Radially symmetric three-phase optimized power control PCB layout

ABSTRACT

Various methods of optimizing the operation of a multiphase electric motor are disclosed, the methods including the step of: activating a series of bottom-side power switches during an off-time interval of the pulse measurement for each of a series of measurement pulse combinations of said motor.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application is a U.S. National Phase Application under 35 U.S.C. §371 of PCT/AU2018/051042 filed on Sep. 21, 2018 which claims priority toAustralian Patent Application No. 2017903859 filed Sep. 22, 2017, thecontents of which applications are incorporated by reference herein intheir entireties.

FIELD OF THE INVENTION

The present invention is directed to the area of control of electricbrushless DC motors (BLDCMs), and, in particular, discloses a sensorlessBLDCM control application, constraint and optimization for compact andefficient dynamically controlled motor systems.

REFERENCES

The following prior art references provide general backgroundinformation in the field.

[1] Midwest Research Institute, BRUSHLESS DC MOTORS, NationalAeronautics and Space Administration, Washington, D.C., 1975

[2] Wikipedia, Brushless DC electric motor,http://en.wikipedia.org/wiki/Bruhless_DC_electric_motor

[3] Muhammad Mubeen, Brushless DC Motors Primer, Radford, Va., 2008

[4] Hendershot J. R. Jr and Miller Tje, Design of BrushlessPermanent-Magnet Motors, Magna Physics Publishing, New York, 1994

[5] Gamazo-Real J., Vazquez-Sanchez E., Gomez-Gil J., Position and SpeedControl of Brushless DC Motors Using Sensorless Techniques andApplication Trends, Open Access, Sensors, 2010

[6] Bhim Singh and Sanjeev Singh, State of the Art on Permanent MagnetBrushless DC Motor Drives, Journal of Power Electronics, Vol. 9, No. 1,January 2009

[7] Atmel Corporation, Atmel AVR928: Scalar Sensorless Methods to DriveBLDC Motors, Application Note 8305B-AVR-07/2013, 2013

[8] Ying Yan and Jian Guo Zhu, A Survey of Sensorless Initial RotorPosition Estimation Schemes for Permanent Magnet Synchronous Motors,Australasian Universities Power Engineering Conference (AUPEC 2004),Brisbane, Australia, September 2004

[9] Schmidt P., Gasperi, M., Ray, G. and Wijenayake A., Initial rotorangle detection of a non-salient pole permanent magnet synchronousmachine, IEEE Industry Applications Society Annual Meeting, New Orleans,1997

[10] Wook-Jin Lee, Seung-Ki Sul, A New Starting Method of BLDC Motorswithout Position Sensor, IEEE, 2004

[11] Shao J., Direct Back EMF Detection Method for Sensorless BrushlessDC (BLDC) Motor Drives, Master of Science Thesis, Faculty of theVirginia Polytechnic Institute and the State University: Blacksburg,Va., USA, September 2003

[12] Yen-Shin Lai and Yong-Kai Lin, Novel Back-EMF Detection Techniqueof Brushless DC Motor Drives for Wide Range Control Without UsingCurrent and Position Sensors, IEEE Transactions on Power Electronics,Vol. 23, No. 2, March 2008

[13] Cheng-Hu Chen and Ming-Yang Cheng, A New Cost Effective SensorlessCommutation Method for Brushless DC Motors Without Phase Shift Circuitand Neutral Voltage, IEEE Transactions on Power Electronics, Vol. 22,No. 2, March 2007

[14] Microchip Technology Inc., Sensorless Field Oriented Control ofPMSM Motors, Application note AN1078, 2007

[15] NXP Semiconductors, Sensorless single-shunt FOC on LPC2900,Application note, December 2009

[16] Texas Instruments, TMS320F28069F, TMS320F28068F, TMS320F28062F,InstaSPIN-FOC Software Technical Reference Manual, Literature Number:SPRUHI9A, January 2014

[17] Gambetta D., Sensorless Technique for BLDC Motors, MPhilDissertation, University of Southern Queensland, Australia, 2006

[18] ELMOS Semiconductor AG, VirtuHall® SENSORLESS PMSM/BLDC MOTORCONTROL COMPETENCE IN AUTOMOTIVE ELECTRONICS, 2007

[19] Steve Mappus, Synchronous Rectification for Forward Converters,Fairchild Semiconductor Power Seminars, 2010-2011

[20] Texas Instruments, LM2747, LM3100, LM5035 Synchronous Rectificationin High-Performance Power Converter Design, Literature Number: SNVA595,2011

[21] Infineon, CX866 Using CCU6E for BLDC control with synchronousrectification (active freewheeling), Application Note AP08078, V1.0,August 2008

[22] STMicroelectronics, PWM MANAGEMENT FOR 3-PHASE BLDC MOTOR DRIVESUSING THE ST7MC, Application Note AN2009, 2007

[23] Jarrad Cody et al., REGENERATIVE BRAKING IN ELECTRIC VEHICLE,Zeszyty Problemowe-Maszyny Elektryczne Nr 81/2009

[24] G. J. Rathod, Prof R. K. JHA, Compact Regenerative Braking Schemefor a PM BLDC Motor Driven Electric Two-Wheeler, International Journalof Scientific Engineering and Applied Science (IJEAS), Volume-2,Issue-4, April 2006

[25] Bo Long et al., Energy-Regenerative Braking Control of ElectricVehicles Using Three-Phase Brushless Direct-Current Motors, Energies2014, 7, 99-144

[26] Jabbals, Automatic Motor Tester Model 4008RJ, www.jabbals.com

[27] Brockhaus Measurements, Rotor Tester, www.brockhaus.com

[28] E. Annie Elisabeth Jebaseeli et al., Real Time TemperatureMeasurement for the Thermal Protection of Switched Reluctance Machine,International Journal of Engineering and Technology, Vol 5 No 3June-July 2013

[29] International Rectifiers, IRFH5300PbF Product Datasheet, PD-97410A

[30] User Manual Flow Competition/Flow WorksTeam

[31] Xerun XR10 Pro User Manual

[32] dDrive Instruction Manual

[33] Jin-Woo Jung, Project #2 Space Vector PWM Inverter, MechatronicSystems Laboratory, Department of Electrical and Computer Engineering,The Ohio State University, February 2005.

BACKGROUND OF THE INVENTION

Any discussion of the background art throughout the specification shouldin no way be considered as an admission that such art is widely known orforms part of common general knowledge in the field.

BLDC Motors:

The sensorless control and operation of BLDC motors is used in a widerange of global market applications owing to their increased energyefficiency and density, compactness, operational reliability and lifeexpectancy. BLDCMs, also known as permanent magnet synchronous motors(PMSM), are generally classified according to their phase windingconfiguration, being either wye or delta and the number of magneticpoles as described in [4].

Sensored BLDCM Control:

The majority of applications employing BLDCM systems in the globalmarket today are designed using the inferior and less efficient sensoredbrushless motor controller technology, outlined in [5]. Generally thesecontroller designs use Hall Effect semiconductor sensors inside themotors to detect rotor position, which increases manufacturing costs dueto extra components and inter-wiring connections required. Whilstsensored motor control systems do not exhibit start-up and low speedoperation problems, the sensors can be subjected to operation at veryhigh temperatures, electric and magnetic interference, assemblyplacement errors leading to reduced energy efficiency and torque, andmechanical failures. As a result, the sensored brushless systems havelower reliability and higher operating costs compared to the sensorlessbrushless technology.

Sensorless BLDCM Control:

Instead of using external sensors, sensorless BLDCM control techniquesuse only electrical measurements obtained from the motor. Those skilledin the art of sensorless BLDCM controller design are familiar with theinherent challenges of operating such motors at and near zero speeds[5], particularly in the presence of demanding dynamic loads. Insensorless brushless operation, issues arise because of the difficultyof obtaining precise BLDCM rotor position information at zero and lowspeeds, which is essential for robust electronic commutation of suchmotors.

There exists a significant amount of prior art related to the design ofsensorless BLDCM controllers [5], [6]. However, it is evident that nosingle controller solution alone can reliably operate motors from startto high speed. Thus generally, sensorless controller designs have to usea hybrid approach, which can encompass one or more of the following keyareas of controller operation: Initial rotor position detection;Sensorless operation at zero and low motor speeds; Sensorless operationat high motor speeds.

Initial Rotor Position Detection:

Initial rotor position detection is the first challenge of sensorlessbrushless controllers to successfully operate a BLDCM from start to highspeed. Most simple techniques in the prior art drive a current throughthe motor windings to force the rotor into a known alignment position.This can result in up to 180° motor rotation opposite to the desireddirection, unwanted overshoot and ringing in the system, and increasedstart-up time. An open loop technique is then generally applied to spinthe motor with a predetermined commutation sequence until sufficientlyhigh speed is reached to allow a sensorless technique such as BEMFvoltage sensing to be employed, for one example as outlined in [7].However, due to the lack of control of synchronization between motorphase currents and voltages, these inferior techniques fail to commutatethe motor properly during start-up in applications where system dynamicsand motor loads are particularly demanding.

More advanced techniques attempt to estimate the actual rotor positionby exciting the motor windings with low level currents and performingelectrical measurements. A comprehensive overview of such prior artinitial rotor position detection techniques is provided in [8]. Broadly,these fall into one of the following: Voltage and reactive powerharmonics; Inductance variation methods; Patterns of voltage and currentvectors; Observer and Kalman filter techniques; Pulse voltage vector;and High frequency signal injection.

Most of these rotor position measurement methods require specializedelectronic hardware circuitry, for example to generate and detect highfrequency injection signals and measure phase currents, which increasesthe size and cost of the controller. Such design requirements make themunattractive for cost sensitive and compact controller brushless motorcontrol applications.

Inductance variation methods are commonly used in rotor positiondetection by exploiting the rotor inherent and magnetic saturationsaliency properties of BLDC motors with a series of short current pulsesapplied to the motor phase windings [9]. The majority of prior artsolutions are focused on phase current measurements to estimate theinitial rotor position [9], [10]. These techniques can have severaldisadvantages.

Firstly, they require specialized electronic hardware circuitry toaccurately measure phase current amplitudes or rise times, whichincreases overall system cost, size and makes them highly sensitive toelectrical noise and measurement errors when operating at hightemperatures, commonly encountered in practical motor controlapplications. Current sensing resistors required in these prior artsolutions also reduce system efficiency and increase power losses.

Secondly, these current sensing techniques require a finite time toraise the inductive currents in motor windings to a measurable levelnecessary for detection. The resultant rotor position detection time canthus take in order of tens of ms, which can be disadvantageous in manyapplications, one example being professional racing of remote controlledelectric vehicles where extremely fast motor starts are crucial.

Thirdly, BLDC motors with stators which exhibit unbalanced (asymmetric)phase winding inductances and resistances can lead to inaccurate initialrotor position detections when using one of these prior art inductancevariation techniques based on phase current measurements, for example,current rise times. Most prior art initial rotor position detectionmethods also assume a BLDCM at standstill (0 RPM).

Power supply voltage variations and fluctuations during initial rotorposition detection and motor start can present another great challengefor sensorless BLDCM controllers in applications where power sourceswith high internal resistance and motors with low phase resistance andinductance are used—for example, battery operated equipment, such asmobility, electric wheel chairs and cordless electric power tools, whichexperience increasing supply voltage variations and fluctuations as thebattery discharges during operation. In the prior art methods based onthe inductance variations measurements, it is evident that this can leadto incorrect rotor position detections and false motor starts.

Sensorless BLDCM Operation:

Numerous sensorless brushless controller techniques have been developedto date to address the challenge of operating BLDCMs across their entirespeed range, ie. from standstill to high speed. An overview of the mostcommon prior art sensorless BLDC motor control solutions is provided in[5] and [6]. These generally fall into one of the following: Direct andindirect BEMF voltage detection methods; BEMF voltage integrationmethods (including third harmonic); Freewheeling diode conductiondetection methods; Estimation and model based methods (FOC, sliding-modeobservers, extended Kalman filters, model reference adaptive systems,adaptive observers, artificial neural networks); Flux linkage variationmethods; and Inductance variation methods

The BEMF voltage detection methods, some detailed examples which can befound in [11], [12], [13] are the simplest of all of the sensorlessbrushless techniques. However, since the BEMF is zero at standstill andproportional to rotational speed, these methods are known to have severelimitations when operating at low motor speeds and as such are onlysuitable for higher, constant speed motor applications, for example,driving motor fans and pumps. These methods generally also requireadditional hardware circuitry, such as described in U.S. Pat. No.6,633,145, which increases overall controller cost.

In an attempt to address the issues of operation at low motor speeds,more complex controllers have been developed employing system model andestimation based methods to operate BLDCMs using field oriented control(FOC) [14], [15]. However, these solutions require a greater systemunderstanding and tuning of motor and controller parameters, whichsignificantly increase development time. These controllers also requiremore complex electronic hardware designs, with very accurate currentmeasurement circuitry, increasing overall system cost, size and reducingefficiency due to power loses in current sensing resistors. The highersystem complexity also makes their practical implementation moredifficult and limits the range of different types of BLDCMs that theycan operate with. Whilst these techniques offer an improvement over BEMFsensing methods, it is evident to those skilled in the field that theystill perform inadequately at start-up and zero and low speeds and aretherefore inoperable in demanding applications such as cordless electricdrills where operation down to motor stall without errors is important.

An example of one of the best FOC sensorless brushless motor controllersolutions used in the industry today, is the InstaSPIN-FOC controllerwhose method is a trade secret of Texas Instruments [16]. Whilst thiscontroller has simplified the task of controller parameter tuningthrough an automated process and features an improved motor performancenear zero speed and when changing direction of motor spin, it is stillinoperable at zero motor speed, or with reversed rotor momentum and canhave unsatisfactory start-up operation under heavy loads. Therefore,there still exists the need to further improve sensorless brushlessmotor operation at start-up and zero speeds.

High performing sensorless BLDCM controller solutions at zero motorspeeds are based on the inductance variation methods in which changesdue to motor phase inductances with respect to rotor position aredetected and used as motor commutation points. One such example isdescribed in [17] (CH698071). In this technique, rotor positiondetection is performed by measuring the voltage response of theopen-phase terminals during PWM on-time and off-time motor drivingswitching intervals. From these +30° advanced timing motor commutationpoints are obtained, however these have the significant disadvantage ofreduced output motor torque and efficiency. Furthermore, as observed inpractice, this technique fails to attain reliable commutation points forall different BLDCMs available on the market and thus the number ofpossible applications using this method is limited in practice.

Another practical example of inductance variation based sensorlessbrushless motor controller is the ELMOS E910.68/88 [18]. By applyingshort (μsec) duration test pulses, this controller detects rotorposition in motion and standstill by measuring the voltage variation atthe motor's neutral point connection. However, this technique is limitedto operation with wye configuration BLDCMs, which must have a fourthmotor connection present. This requires an additional hardwareconnection which is inconvenient for most brushless motor systems andadds to their cost. This sensorless brushless control realization isalso unsuitable for delta winding BLDCMs commonly used in high powermotor systems, such as cordless electric power tools, because they donot have this fourth neutral point connection. Therefore, the range ofpossible motor applications with this controller is limited.

Starting and operating BLDCMs with reversed rotor momentum or in systemsemploying gearboxes that generate backlash disturbances presents afurther challenge for sensorless brushless motor control applications,for example, commonly experienced in mobility equipment and cordlesselectric power tools. The prior art solutions may not explicitlyaddressed these challenges either.

Synchronous Rectification:

Synchronous rectification (SR) is a technique used in inductive load PWMswitching applications to reduce controller power losses. Instead offreewheeling PWM off-time currents through a diode, an activesemiconductor device, such as a MOSFET or IGBT transistor with a lowerresistance path is used, thus improving efficiency. A review of thismethod is presented in [19]. Synchronous rectification is most commonlyapplied in switching power converters, such as DC/DC power supplies, forexample described in [20]. This method generally requires specializedelectronic hardware circuitry to optimally control rectification on-timeduration in response to inductive PWM off-time currents flowing duringeach PWM cycle, resulting in increased system cost and size and for thisreason synchronous rectification is less common in BLDCM controlapplications. Furthermore, it is evident to the inventor of thisdisclosure, that implementation of optimally controlled synchronousrectifiers in PWM switching sensorless BLDCM control applications ischallenging, because they can potentially interfere with sensorlessdetection and operation.

Practical examples of synchronous rectification in sensored andsensorless BLDCM control applications are presented in [21] and [22]respectively. The control approaches presented in these prior artsolutions, however, use a simpler technique with fixed durationrectifier timing synchronized to the PWM off-time to actively controlmotor inductive currents. This non-optimal method activates the lowerresistance rectifier devices for the entire PWM off-time duration, whichcan in practice lead to unwanted motor braking during operation athigher motor speeds and lighter loads, resulting in increased systemenergy losses. This problem is undesirable in many motorapplications—one example being mobility equipment.

Regenerative Motor Braking:

A general primer of regenerative braking technologies used in BLDCmotors today is provided in [23], [24], [25]. There is little prior arton regenerative motor braking applications employing synchronousrectification, particularly in sensorless BLDC motor applications.

Rotor Magnetic Field Strength Measurement:

Brushless DC motors use rotors consisting of magnets and to determinetheir condition some form of rotor magnetic field strength measurementis performed. This is desirable in many motor applications operating inhigh temperature environments, one example being professional racing ofremote controlled electric vehicles, where extreme temperatures degradea rotor's magnetic field and thus motor performance. Currently thistesting process is highly inaccurate and subjective because theoperators try to feel the strength of the magnets simply by rotating therotor shaft with their fingers. In such applications a rotor magneticfield strength measurement is desirable to determine the magnetic stateof the rotor and when it needs to be replaced.

Prior art methods of measuring the magnetic field strength of a rotorcan employ expensive measurement equipment, such as described in [26]and [27]. However, these measurements must be performed manually withthe system off-line and require disassembly of the motor to access therotor, which can be labour intensive and a costly maintenance procedure.It would be desirable if an alternative could be provided.

Little prior art exists in this challenging area of brushless motorcontrol application, particularly when attempting to address thisproblem with an automatic rotor magnetic field strength measurementbuilt into the BLDC motor controller. One reason is that the existingcontroller solutions use unsuitable methods of approach, which make itdifficult to address this challenge.

Motor Temperature Measurement:

BLDCM applications operating in high ambient temperature environments orunder high loads require monitoring of internal motor temperature inorder to prevent motor winding damage in the event of excessivetemperatures. The known prior art methods of motor temperaturemonitoring use either temperature sensors mechanically placed near thecopper windings, non-contact measurement employing infra-red (IR)thermometry, or copper winding resistance measurement techniques, asdescribed in [34].

These methods require either expensive sensors, such as resistancetemperature detectors, thermocouples or infrared sensors, mechanicalhardware to mount sensors near the motor windings, interconnectionwiring and electronic circuitry to measure the motor temperature duringoperation, significantly increasing the system cost. It would beadvantageous if an alternative was provided.

Three-phase Power Control PCB Layout:

With today's modern semiconductor switching devices, such as surfacemount technology MOSFETs which are available with ultra lowon-resistance values, typically less <2 mΩ [29], the layout design ofthe printed circuit board (PCB) containing these power switching devicesto control the phase currents becomes important in three-phase powercontrol applications, such as BLDC motors. When these power transistorsare paralleled to decrease the total resistance and increase the maximumcurrent capability of the controller, the total PCB copper trackresistance can be significant, resulting in higher overall power lossesand heating of the controller during high current demanding powerapplications.

One BLDCM industry example where controller's power PCB layout designpresents a challenge is the professional R/C electric vehicle racing,where compact, small footprint PCB layouts are used to reduce the sizeof the controller, such as described in [30] and [31]. This sizerequirement places tremendous stress on thermal and cooling needs ofthese BLDCM controllers. Currently, motor controllers available in thisindustry use a rectangular shape PCB layout design with all power wiresexiting on one side of the controller, for example as shown in [30] and[31] for two leading R/C motor controller manufacturers. This PCB layoutand power wire connection configuration is not optimal for three-phaseBLDCM controller applications. It would be advantageous if an improvedlayout was provided.

Another three-phase power control application where the PCB layoutdesign is critical is BLDC motors with motor controllers integratedinside the motor, such as the R/C electric vehicles motor systemdescribed in [32]. The combined power losses of the BLDC motor statorcopper windings and three-phase BLDCM power controller electronics inthese motor systems, which are located in the same unit, present an evengreater thermal and power cooling challenge. It is evident that in thesemotor systems which generally use power transistors mounted in arectangular configuration on the PCB, such as shown in [32], furtherperformance improvements are also possible with a different PCB layoutconfiguration.

SUMMARY OF THE INVENTION

It is an object of the invention, in its preferred form to provide foran improved form of electric motor controller.

Initial Rotor Position State Determination

In accordance with a first aspect of the present invention, there isprovided a method of optimizing the operation of a multiphase electricmotor, the method including the step of: activating a series ofbottom-side power switches during an off-time interval of the pulsemeasurement for each of a series of measurement pulse combinations

In accordance with a further aspect of the present invention, there isprovided a method of optimizing the operation of a multiphase electricmotor, the method including the step of: measuring on-time (Vs) andoff-time (Vs_off) supply voltages to correct open phase voltagemeasurements (Von, Voff) for power supply voltage fluctuations

In accordance with a further aspect of the present invention, there isprovided a method of optimizing the operation of a multiphase electricmotor, the method including the step of: measuring both on-time (Von)and off-time (Voff) of open phase winding voltages to deduce the rotorposition within the electric motor.

In accordance with a further aspect of the present invention, there isprovided a method of optimizing the operation of a multiphase electricmotor, the method including the step of: applying a preceding shortduration pulses to demagnetize the multiphase stator core.

In accordance with a further aspect of the present invention, there isprovided a method of optimizing the operation of a multiphase electricmotor, the method including the step of: correlating the on-time (Von)and off-time (Voff) open phase voltages using on-time (Vs) and off-time(Vsoff) supply voltage measurements.

In accordance with a further aspect of the present invention, there isprovided a method of optimizing the operation of a multiphase electricmotor, the method including the step of: calculating an initial rotorposition with a series of developed rotor position functions (RPF).

In accordance with a further aspect of the present invention, there isprovided a method of optimizing the operation of a multiphase electricmotor, the method including the step of: calculating initial rotorposition utilizing an absolute rotor position calculation method.

In accordance with a further aspect of the present invention, there isprovided a method of optimizing the operation of a multiphase electricmotor, the method including the step of: determining motor rotationdirection with a series of developed rotation direction functions (RDF).

In accordance with a further aspect of the present invention, there isprovided a method of optimizing the operation of a multiphase electricmotor, the method including the step of: applying all of the aboveinitial rotor position detection methods to measurements made with openphase current amplitudes or rise times.

Zero to Low Speed Sensorless BLDCM Operation

In accordance with a further aspect of the present invention, there isprovided a method of optimizing the operation of a multiphase electricbrushless DC motor (BLDCM), the method including the step of: applying athree interval PWM phase current control method to drive the BLDCM witha predetermined phase coil commutation sequences.

In accordance with a further aspect of the present invention, there isprovided a method of optimizing the operation of a multiphase electricbrushless DC motor (BLDCM), the method including the step of: insertingan on-time and off-time open phase winding and power supply voltagemeasurement pulses at the end of three interval PWM phase currentcontrol pulses to determine rotor position (commutation points) androtation direction.

In accordance with a further aspect of the present invention, there isprovided a method of optimizing the operation of a multiphase electricbrushless DC motor (BLDCM), the method including the step of: activatinga series of bottom-side power switches during an off-time interval ofthe pulse measurements to deduce BLDCM commutation points and rotationdirection

In accordance with a further aspect of the present invention, there isprovided a method of optimizing the operation of a multiphase electricbrushless DC motor (BLDCM), the method including the step of: measuringboth on-time (Von) and off-time (Voff) open phase winding voltages todeduce commutation points and rotation direction.

In accordance with a further aspect of the present invention, there isprovided a method of optimizing the operation of a multiphase electricbrushless DC motor (BLDCM), the method including the step of: measuringon-time (Vs) and off-time (Vs_off) supply voltages to correct open phasevoltage measurements (Von, Voff) for power supply voltage fluctuations.

In accordance with a further aspect of the present invention, there isprovided a method of optimizing the operation of a multiphase electricbrushless DC motor (BLDCM), the method including the step of:correlating the on-time (Von) and off-time (Voff) open phase voltagesusing on-time (Vs) and off-time (Vsoff) supply voltage measurements.

In accordance with a further aspect of the present invention, there isprovided a method of optimizing the operation of a multiphase electricbrushless DC motor (BLDCM), the method including the step of:calculating zero to low speed sensorless BLDCM commutation points with apredetermined commutation point function (CPF).

In accordance with a further aspect of the present invention, there isprovided a method of optimizing the operation of a multiphase electricbrushless DC motor (BLDCM), the method including the step of:calculating zero to low speed sensorless BLDCM commutation pointsobtained from predetermined possible combinations of correlated on-time(Von) and off-time (Voff) open phase voltage measurements of said motor.

In accordance with a further aspect of the present invention, there isprovided a method of optimizing the operation of a multiphase electricbrushless DC motor (BLDCM), the method including the step of:determining motor rotation direction during sensorless BLDCM operationwith a method consisting of rotor position functions (RPF) and/orrotation direction functions (RDF).

In accordance with a further aspect of the present invention, there isprovided a method of optimizing the operation of a multiphase electricbrushless DC motor (BLDCM), the method including the step of: utilizingcorrelated on-time (Von) and off-time (Voff) measurements from twoconsecutive three-interval PWM cycles of the motor to reduce the numberof open phase voltage measurement pulses required to calculatecommutation point functions (CPFs) and rotation direction functions(RDFs).

In accordance with a further aspect of the present invention, there isprovided a method of optimizing the operation of a multiphase electricbrushless DC motor (BLDCM), the method including the step of: applying aquasi field oriented control (QFOC) method to increase motor torqueduring zero to low sensorless BLDCM operation.

Low to High Speed Sensorless BLDCM Operation

In accordance with a further aspect of the present invention, there isprovided a method of optimizing the operation of a multiphase electricbrushless DC motors (BLDCM), the method including the step of: using aCPFmax value measured during zero to low speed sensorless BLDCMoperation to obtain quasi 0° timing L→H and H→L commutation point (CP)voltage thresholds for low to high speed sensorless BLDCM operation.

In accordance with a further aspect of the present invention, there isprovided a method of optimizing the operation of a multiphase electricbrushless DC motors (BLDCM), the method including the step of: using theCPFmax value to obtain an optimum commutation point with automatic motortemperature compensation

In accordance with a further aspect of the present invention, there isprovided a method of optimizing the operation of a multiphase electricbrushless DC motors (BLDCM), the method including the step of: applyinga software controlled PWM synchronous rectification method during thePWM off-time interval to increase controller efficiency and motortorque.

In accordance with a further aspect of the present invention, there isprovided a method of optimizing the operation of a multiphase electricmotor, the method including the step of: applying the above methods tohigh-side only, low-side only or alternate low-high side PWM switchingtopologies during sensorless BLDCM operation

Rotor Magnetic Field Strength Measurement

In accordance with a further aspect of the present invention, there isprovided, in a power controller for controlling a motor system, a methodof measuring the rotor magnetic field strength, the method including thestep of: using the maximum computation point function value measuredfrom computation point function value measurements during zero to lowspeed sensorless BLDCM operation to obtain an indication of the rotormagnetic field strength

Motor Temperature Measurement

In accordance with a further aspect of the present invention, there isprovided, in a power controller for controlling a motor system, a methodof measuring the motor temperature, the method including the step of:using a maximum computation point function value measured fromcomputation point function during zero to low speed sensorless BLDCMoperation to obtain an indication of the motor temperature

Regenerative Motor Braking

In accordance with a further aspect of the present invention, there isprovided a method of optimizing the operation of a multiphase electricmotor, the method including the step of: using a software controlled PWMsynchronous rectification method during a PWM off-time interval toincrease controller efficiency and amount of energy returned to thepower source during motor braking

In accordance with a further aspect of the present invention, there isprovided a method of optimizing the operation of a multiphase electricmotor, the method including the step of: applying a software controlledsynchronous rectification method to high-side only, low-side only oralternate low-high side PWM switching topologies during regenerativemotor braking.

In accordance with a further aspect of the present invention, there isprovided a method of optimizing the operation of a multiphase electricmotor, the method including the step of: applying the motor regenerativebraking methods in all electric motor applications, such as sensorlessbrushless, sensored brushless and brushed motors

Software Controlled Synchronous Rectification

In accordance with a further aspect of the present invention, there isprovided a method of optimizing the operation of a multiphase electricmotor, including implementing a software controlled synchronousrectification including the step of: (a) implementing a controlledsynchronous rectification duration (T_(SR)) during which the rectifierpower switch is activated; (b) providing at least two distinct modes ofoperation: when T_(SR)<PWM off-time period (T_(OFF)) and whenT_(SR)=T_(OFF); (c) measuring a feedback voltage (V_(FB)) at the end ofsynchronous rectification interval (T_(SR)); and (d) using feedbackvoltage to optimally regulate the active synchronous rectificationduration (T_(SR)).

In accordance with a further aspect of the present invention, there isprovided a method of optimizing the operation of a multiphase electricmotor, the method including the step of: applying a software controlledsynchronous rectification method to high-side only, low-side only oralternate low-high side PWM switching topologies during inductive loadswitching applications.

In accordance with a further aspect of the present invention, there isprovided a method of optimizing the operation of a multiphase electricmotor, the method including the step of: applying a software controlledPWM synchronous rectification method in all inductive load switchingapplications such as DC/DC power supplies, during motor driving andbraking operations of brushed, sensorless brushless and sensored brushedmotors

Radially Symmetrical Three-phase Optimized Power Control PCB Layout

In accordance with a further aspect of the present invention, there isprovided a method of optimizing the layout of power control circuitry,of a multi phase power controller, the method including the step of:placing groups of single or paralleled power transistors (low-side andhigh-side switching) belonging to each phase in a radial symmetry aboutthe center of a PCB.

In some embodiments, the power transistors are placed on the top orbottom PCB layers.

In some embodiments, the method can include placing phase output powerwire PCB connections in the middle of each power transistor groupgeometry to physically reduce the PCB copper track resistance in eachphase.

In some embodiments, the method can include only the low-side or thehigh-side switching power transistors on one side of the PCB. In someembodiments, the method can include the power transistors are placed onboth the low-side or the high-side switching power transistors on oneside of the PCB

In accordance with a further aspect of the present invention, there isprovided a method of optimizing the layout of power control circuitry,of a multi phase power controller, the method including the step of:applying a radially symmetrical PCB design in three-phase power controlapplications such as R/C electric vehicle BLDC motor controllers andBLDC motors with the PCB and controller hardware built inside the motor.

BRIEF DESCRIPTION OF THE DRAWINGS

Embodiments of the invention will now be described, by way of exampleonly, with reference to the accompanying drawings in which:

FIG. 1 illustrates a disclosed hybrid sensorless brushless DC motorcontroller operation flowchart.

FIG. 2 illustrates a disclosed sensorless brushless DC motor controllercircuitry.

FIG. 3 illustrates a phase winding inductance variation due to rotorinherent saliency (prior art).

FIG. 4 illustrates a phase winding inductance variation due to rotorinherent and magnetic saturation saliency (prior art).

FIG. 5 illustrates a phase winding inductance variation detection usingfixed current threshold to measure current rise times (prior art).

FIG. 6 illustrates a phase winding inductance variation detection usingfixed current rise time to measure current amplitudes (prior art).

FIG. 7 illustrates a phase winding inductance variation detection usingopen phase on-time voltage measurements (prior art).

FIG. 8 illustrates a phase winding inductance variation detectionemploying a short duration phase coil excitation pulse and on-time andoff-time open phase winding and supply voltage measurements.

FIG. 9 illustrates an initial rotor position detection phase windingpulsing sequence employing on-time and off-time open phase and supplyvoltage measurements with six preceding stator core demagnetizationshort duration pulses.

FIG. 10 illustrates an initial rotor position detection phase windingpulsing sequence employing on-time and off-time open phase and supplyvoltage measurements with three preceding stator core demagnetizationshort duration pulses for the case when supply voltage is fluctuating.

FIG. 11 illustrates a calculated rotor position function output vselectrical rotor position.

FIG. 12 illustrates a calculated +30° shifted rotor position functionoutput vs electrical rotor position.

FIG. 13 illustrates a rotor position function output vs electrical rotorposition calculated in a BLDCM exhibiting flat regions and kinks at the60° sector zero-crossings.

FIG. 14 illustrates an enhanced rotor position function output vselectrical rotor position calculated for the BLDCM with RPF (PA, PB, PC)outputs shown in FIG. 13, resulting in removal of the flat regions andkinks at the 60° sector zero-crossings and increased rotor positiondetection accuracy.

FIG. 15 illustrates an absolute rotor position obtained withtrigonometric calculations providing increased angular resolution forthe practical BLDCM with RPF (PA, PB, PC) outputs shown in FIG. 11.

FIG. 16 illustrates a rotor position and rotation direction detectionflowchart with RPFs.

FIG. 17 illustrates a rotor position and rotation direction detectionflowchart with RPFs and ERPFs.

FIG. 18 illustrates an absolute rotor position calculation and rotationdirection detection flowchart.

FIG. 19 illustrates a phase current and voltage waveforms during asingle cycle of the three intervals PWM method used to generate the BLDCmotor driving torque.

FIG. 20 illustrates a zero to low speed sensorless BLDC operation in the1st embodiment showing one PWM cycle pulses (PWMT1-3) and four pairs ofVon and Voff phase measurement pulses used in commutation point (CPD)and rotation direction detection (RDD).

FIG. 21 illustrates a zero to low speed sensorless BLDC operation in the2nd embodiment (Δ) showing one PWM cycle pulses (PWMT1-3) and six pairsof Von and Voff phase measurement pulses used in commutation point (CPD)and rotation direction detection (RDD).

FIG. 22 illustrates correlated Von and Voff open phase voltagemeasurements in a practical BLDCM.

FIG. 23 illustrates CPFs calculated for BLDCM with correlated Von andVoff open phase measurements shown in FIG. 22.

FIG. 24 illustrates an extension to CPD using only Von (or Voff)measurements from consecutive PWM T1-T3 cycles to calculate CPFs,implemented to reduce the number of required Von measurement pulses ineach PWM cycle from 2 to 1.

FIG. 25 illustrates a zero to low speed sensorless BLDCM controlleroperation flowchart.

FIG. 26 illustrates a zero to low speed sensorless BLDCM controllercommutation point detection and phase winding switching states includingQFOC ( - - - ) (1st embodiment).

FIG. 27 illustrates a zero to low speed sensorless BLDCM controllercommutation point detection and phase winding switching states includingQFOC ( - - - ) (2nd embodiment (Δ)).

FIG. 28 illustrates a rotor magnetic field strength measurement based onCPFmax values measured during zero to low speed sensorless BLDCMoperation for different motors with increasing rotor magnetic fieldstrengths.

FIG. 29 illustrates a rotor magnetic saliency ratio vs CPFmax curves forincreasing rotor magnet temperature.

FIG. 30 illustrates a rotor magnetic saliency ratio variation with motortemperature measured in a 25.5 turn wye winding BLDCM.

FIG. 31 illustrates a sensorless motor temperature measurement in a BLDCmotor employing straight line approximation and two pairs of motortemperature and magnetic field strength saliency ratio (CPFmaxR)measurements at cold (CPFmaxR_T1, T1) and hot (CPFmaxR_T2, T2) motortemperatures.

FIG. 32 illustrates a low to high speed sensorless BLDCM operation PWMswitching intervals, with optimal software controlled synchronousrectifier duration (TSR) active during PWM off-time.

FIG. 33 illustrates a low to high speed sensorless BLDCM operation H→Land L→H commutation point detection voltage thresholds employing CPFmaxmeasurements during PWM on-time switching interval.

FIG. 34 illustrates a low to high speed sensorless BLDCM controlleroperation flowchart.

FIG. 35 illustrates a software controlled synchronous rectificationintegrated in the PWM off-time interval during low to high speedsensorless BLDC motor operation, showing the optimum synchronousrectifier duration TSR controlled via the feedback voltage VFBmeasurement.

FIG. 36 illustrates a low to high speed sensorless BLDCM controllercommutation point detection employing inductance voltage variations,showing the corresponding phase winding switching states during PWMon-time and synchronous rectifier operation during PWM off-time.

FIG. 37 illustrates an inductive load PWM switching phase voltage andcurrent waveforms employing freewheeling diode during PWM off-time,showing the region of power loss (Pd_FW) indicated by the hashed linearea (prior art).

FIG. 38 illustrates PWM on-time circuit connections during BLDCMinductive load switching.

FIG. 39 illustrates a PWM off-time freewheeling diode switching intervalduring BLDCM inductive load operation.

FIG. 40 illustrates inductive load PWM switching phase voltage andcurrent waveforms employing synchronous rectifier during PWM off-time,showing the reduced region of power loss (Pd_SR) indicated by the hashedline area (prior art).

FIG. 41 illustrates a PWM off-time synchronous rectifier switchinginterval during BLDCM inductive load operation.

FIG. 42 illustrates a software synchronous rectifier feedback controlleroperation at low inductive loads with IFB>0, resulting in feedbackvoltage VFB>0.

FIG. 43 illustrates a software synchronous rectifier feedback controlleroperation at low loads with IFB<0, resulting in feedback voltage VFB<0.

FIG. 44 illustrates a software synchronous rectifier feedback controlleroperation at high loads with IFB>0, resulting in feedback voltage VFB<0.

FIG. 45 illustrates a software synchronous rectifier feedback controlleroperation at high loads with IFB<0, resulting in feedback voltage VFB>0.

FIG. 46 illustrates a software controlled synchronous rectificationoperation flowchart.

FIG. 47 illustrates a regenerative BLDC motor braking sensorlesscommutation point detection, showing PWM switching intervals and theoptimal software controlled synchronous rectifier duration (TSR) activeduring PWM off-time.

FIG. 48 illustrates a software controlled synchronous rectificationapplied in the PWM off-time interval during regenerative motor brakingoperation, showing the optimum synchronous rectifier duration TSRcontrolled via the feedback voltage VFB measurement.

FIG. 49 illustrates a sensorless BLDC motor regenerative brakingoperation flowchart, integrating the optimal software controlledsynchronous rectifier duration TSR.

FIG. 50 illustrates a sensorless BLDC motor regenerative brakingcommutation map showing BEMF waveforms, commutation detection points andcorresponding phase winding switching states during PWM on-time,synchronous rectifier operation and PWM off-time (I=0).

FIG. 51 illustrates one embodiment of a rectangular power PCB layoutused in three-phase power control applications, showing paralleled powertransistors in a rectangular configuration that results in increasedphase (A, B, C) output resistances, unbalanced phase impedances andresistances, and temperature hot spots in the middle power transistorgroup (B1-B4) (prior art).

FIG. 52 illustrates a top view of PCB copper track connections, externalpower wire pad connections and through hole via connections to internaland bottom PCB layers of one embodiment of rectangular power PCB layoutin FIG. 51 (prior art).

FIG. 53 illustrates a top view of one embodiment of a radiallysymmetrical power PCB layout for three-phase power control applications,showing groups of paralleled power transistors in each phase (A, B, C)placed in a “bent” 4×1 configuration with radial symmetry around thecenter of the PCB and power wire connection tabs placed in the middle ofeach group of power transistors, resulting in reduced phase outputresistance, power losses and power transistor temperature hot spots andmore balanced phase impedances and resistances.

FIG. 54 illustrates a top view of another embodiment of a radiallysymmetrical power PCB layout design for three-phase power controllerapplications, consisting of groups of paralleled power transistors ineach phase (A, B, C) placed in a 2×2 square configuration with radialsymmetrically around the center of the PCB and with power wireconnection tabs placed in the middle of each group of power transistors.

FIG. 55 illustrates a top view of another embodiment of a radiallysymmetrical power PCB layout design for three-phase power controllerapplications, consisting of groups of paralleled power transistors ineach phase (A, B, C) placed in a 4×1 straight-line configuration withradial symmetrical around the center of the PCB and with power wireconnection tabs placed in the middle of each group of power transistors.

FIG. 56 illustrates a top view of one embodiment of a radiallysymmetrical power PCB layout of the PCB embodiment in FIG. 54, showingonly the low-side switching power transistor groups (A1-A4, B1-B4,C1-C4) belonging to each phase, and their PCB electrical connections.

FIG. 57 illustrates a top view of another embodiment of a radiallysymmetrical power PCB layout of the PCB embodiment in FIG. 54, showingboth the low-side switching power transistor groups (A1-A2, B1-B2,C1-C2) and the high-side switching power transistors groups (A3-A4,B3-B4, C3-C4) placed on the same PCB layer and their PCB electricalconnections.

FIG. 58 illustrates a top PCB layer view of one embodiment of a radiallysymmetrical power PCB layout design for three-phase power controllerapplications, showing the low-side switching power transistors (A1-A4,B1-B4, C1-C4), PCB copper track connections, external power wire padconnections and via connections to internal and bottom PCB layers.

FIG. 59 illustrates a bottom PCB layer view of one embodiment of aradially symmetrical power PCB layout design for three-phase powercontroller applications, showing the high-side switching powertransistors (A5-A8, B5-B8, C5-C8), PCB copper track connections,external power wire pad connections and via connections to internal andtop PCB layers.

FIG. 60 illustrates a first internal PCB layer view of one embodiment ofa radially symmetrical power PCB layout design for three-phase powercontroller applications.

FIG. 61 illustrates a second internal PCB layer view of one embodimentof a radially symmetrical power PCB layout design for three-phase powercontroller applications.

FIG. 62 illustrates a rectangular PCB layout phase resistance model ofrectangular PCB layout embodiment in FIG. 52, consisting of a group offour power transistors (Rt) and interconnecting PCB copper trackresistances (R) (prior art).

FIG. 63 illustrates a radially symmetrical PCB layout phase resistancemodel of radially symmetrical PCB layout embodiment in FIG. 58consisting of a group of four power transistors (Rt) and interconnectingPCB copper track resistances (R).

FIG. 64 illustrates a normalized total PCB phase resistance comparisonbetween the prior art rectangular PCB layout of embodiment in FIG. 52and the disclosed radially symmetrical PCB layout of embodiment in FIG.58, with the unit copper PCB track resistance R=1 and varying normalizedpower transistor resistance (Rt), showing ≈40-50% phases resistancereduction.

DETAILED DESCRIPTION

The embodiments are directed to the area of control of electricbrushless DC motors (BLDCMs), with a particular focus on the sensorlessBLDCM control application, constraint and optimization for compact andefficient dynamically controlled motor systems—one example beingcordless electric power tools. The application and technology relategenerally to the challenges of creating effective and efficientsensorless BLDCM control to manage the performance and life cycle ofsuch electric motors. A set of challenges for sensorless BLDCMcontrollers are apparent, which translate across a large set ofapplications and realizations, these are:

Motor start at standstill and in motion; Motor start with reversed rotormomentum; Motor start in presence of external load disturbances, gearboxbacklash; Motor start time and response; Motor operation and torquecontrol down to stall (0 RPM), at low speed, with reversed rotormomentum, dynamic loads and external disturbances; Controller operationwith a broader range of BLDCMs available on the market (salient andnon-salient pole, wye and delta winding, asymmetric stator phase windinginductances and resistances); Controller efficiency during motoroperation, regenerative motor braking; Energy return to the power sourceduring regenerative motor braking; Controller sensitivity to supplyvoltage and temperature variations, noise; Controller setup and tuning,integration time; Controller electronic circuit design complexity, size,cost; Motor and controller system reliability, operation and maintenancecost; Rotor magnetic field strength measurement in real time andmonitoring over life time of operation; Motor temperature measurementand monitoring in real time; Printed circuit board (PCB) layoutoptimization in three-phase power control applications.

The embodiments provide for sensorless BLDCM controller designs thathave improved performance, operational behaviour and greater possibilityacross one or more of these areas of challenge. As such, the disclosureof the embodiments is applicable to a wide area, and more broadlyapplicable to the application of BLDCMs across applications, includingand not limited to power tools, locomotion, mobility, robotics,automation and control, automotive, medical, consumer, computer, hobby,etc. A general primer of the breadth and applicability of the areas ofinterest and application of BLDCMs can be found in The following priorart references provide general background information in the field.

[1], [2], [3].

The embodiments provide an initial rotor position detection whichpresents a method that is insensitive to phase winding asymmetries inBLDCMs.

The embodiments provide an improved inductance variation techniqueemploying only voltage measurements to detect the initial rotor positionand as such do not require any additional electronic circuitry. Thedisclosed technique also makes it possible to detect the initial rotorposition of a wide range of BLDCMs extremely fast, typically in <1 ms,whilst doing so with greater accuracy and precision.

The embodiments specifically address the challenges of detecting theinitial rotor position with the motor already spinning at very lowspeeds, for example, below the BEMF voltage measurement threshold, orwhen starting with a reversed rotor momentum. These sensorless brushlessmotor control challenges are frequently encountered in applications,such as mobility equipment and cordless electric power tools.

The synchronous rectification method disclosed in the embodimentsprovides a near optimal, software controlled approach that integratesseamlessly into the sensorless BLDCM operation during PWM switching anddynamic regenerative motor braking. This is achieved without anyadditional electronic hardware circuitry, leading to furtherimprovements in controller output efficiency under all motor loads. Itis evident that the disclosed synchronous rectification method can alsobe applied to any other inductive PWM switching applications. Forexample, DC/DC power supplies, brushed and sensored brushless motors.

The novel software controlled synchronous rectification techniquedisclosed in the embodiments can be used to increase controllerefficiency and the amount of energy recycled back into the power sourceduring motor braking. It can thus improve the performance of batteryoperated motor applications, such as mobility equipment, by increasingthe time before battery recharging is required.

An innovative step of the disclosed controller embodiments is theability to measure a BLDCM's rotor magnetic field strength duringoperation without requiring any additional hardware or electroniccircuitry. It is also possible to monitor the rotor magnetic fieldstrength over the entire life cycle of operation. In many brushlessmotor applications such a built-in, automatic rotor measurement can havethe advantage of decreasing operation and maintenance costs andincreasing system performance.

The embodiments disclose a novel BLDC motor temperature measurement thatdoes not require any additional temperature sensing equipment, hardwareor electronic circuitry. The disclosed method uses electrical motormeasurements obtained during sensorless BLDCM mode of operation fromwhich reliable motor temperature measurements in real time of operationare obtained.

To address power and thermal loss challenges in three-phase powercontrol applications, the embodiments also disclose a novel PCB layoutdesign consisting of power transistors placed in a radially symmetricalconfiguration that achieves a significant reduction in the PCB coppertrack resistance in each phase compared to the prior art, reducing powerand thermal losses and increasing controller efficiency.

The sensorless brushless DC motor controller of the preferred embodimentexploits the inductance variations which exist in BLDC motors due torotor inherent and magnetic saturation (RIMS) saliency. The disclosedcontroller methods improve the accuracy, precision and speed of initialrotor position detection compared to the prior art and extend theinductance variation properties to novel commutation point detectionmethods for sensorless operation of BLDC motors at zero and high speeds.The disclosed sensorless BLDCM control operation is highly robust duringstart-up and operation at near zero speed, providing torque control downto motor stall and operation with reversed rotor momentum with a broaderrange of wye and delta configuration BLDCMs. The disclosed sensorlessBLDCM controller is also independent of motor parameters and usessimplified hardware circuitry that requires only voltage measurements,making it easier and cheaper to implement in practical applications.

As will be further described below, the embodiments disclose a hybridsensorless BLDCMs control approach, as illustrated by the flow chart 1of FIG. 1, to address a set of BLDC motor control system challengesacross a large set of applications and realizations and extends motorcontroller innovation in the following key areas: Initial rotor positiondetection; Zero to low speed sensorless BLDCM operation; Low to highspeed sensorless BLDCM operation; BLDC motor regenerative braking; PWMsynchronous rectification; and Rotor magnetic field strength and motortemperature measurement.

To address the controller challenge of robust sensorless brushlessoperation with the broadest possible range of BLDC motors, two differentcontroller embodiments are disclosed with the second embodiment denotedwith the Δ suffix.

To proceed with the description, it is instructive to introduce somebrushless motor controller background information.

A Sensorless BLDCM Controller Circuit

The basic equivalent circuit for the control of the BLDCM according tothe disclosed embodiments is illustrated 20 in FIG. 2. The sensorlessBLDCM control system includes:

BLDC motor 21 with a stator consisting of plurality of coil phasewindings, wye or delta phase winding configuration (FIG. 2 depicting adelta winding), a rotor 22 which includes a permanent magnet, arrangedto rotate in or around the stator of the motor.

BLDC motor switching control circuit 23 consisting of plurality ofsemiconductor power transistor switches (A_L, A_H, B_L, B_H, C_L, C_H)such as MOSFETs or IGBTs to control the phase winding currents in asynchronized manner with the rotor position and includes freewheelingsemiconductor diodes e.g. 24 to conduct off-time switching inductivecurrents.

Power transistor gate control circuit consisting of plurality of gatedrivers (A_L, A_H, B_L, B_H, C_L, C_H) 27 to optimally control the powertransistors 23 during switching operation. Additionally, an Analog todigital converter circuit 29, consisting of high speed plurality ofanalog voltage measurements (Va, Vb, Vc), which can include voltageresistor divider networks to reduce the sampled analog voltages to anacceptable level for measurement with an ADC and capacitors to reducemeasured analog voltage bandwidth and filter out electrical noise.

A Microcontroller 28 provides various functionalities according to thevarious embodiments. The controller may comprise an integrated highspeed ADC circuit, volatile memory such as DRAM, and non-volatile memorysuch as PROM, EPROM, EEPROM, FLASH, MRAM, PCRAM, and otherfunctionalities such as input and output interfacing, and communicationports etc.

Electrical voltage source (Vs) such as a transformer or a switchingpower supply or a battery.

Rotor Inherent Saliency

If the flux from the permanent magnets in the rotor is large enough tomagnetically saturate the stator iron in a BLDC motor, then a variationin the rotor's direct and quadrature magnetic axes with respect to thestator coils leads to a variation in phase inductance shown 30 in FIG.3. When the permanent magnet rotor flux is fully aligned (direct) withthe stator coil the iron stator core is maximally saturated whichreduces the coil's inductance (90° and 270° rotor positions 31, 32).When the permanent magnet rotor flux is perpendicular (quadrature) tothe stator coil, no iron stator coil saturation occurs and theinductance is largest (0° and 180° rotor positions 33, 34).

Magnetic Saturation Saliency

If current is flowing through the phase coils of a permanent magnet BLDCmotor, then the flux produced by the phase coils in the stator interactswith the flux from the permanent magnet rotor, leading to additionalvariations in the troughs of the phase inductances as illustrated 40 inFIG. 4. When the north-pole is aligned with the phase coil, the currentincreases the flux linked by the coil, resulting in increasing statorsaturation and slightly decreasing the phase inductance (270° rotorposition 41). When the south-pole is aligned with the coil, the currentin the phase coil decreases the flux linked by the coil, decreasingstator saturation and slightly increasing the phase inductance (90°rotor position 42). By measuring these variations in inductance of thecoils, it is possible to detect the position of the permanent magnetrotor [9].

Inductance Variation Measurement

In the embodiments, phase coils inductance variation due to RIMSsaliency is measured indirectly as a voltage variation at the output ofinactive (open) phase coil after applying a short duration current pulseto a pair of phase coils. This open phase winding voltage measurementtechnique is different to the prior art, such as disclosed in U.S. Pat.Nos. 5,028,852, 5,191,270, 6,172,498, 6,850,863, 7,023,155, 7,489,096,7,592,761, 7,944,159, WO 2012/010065, U.S. Pat. Nos. 8,400,086,8,796,974, where current variations due to phase inductance changes aremeasured in deducing the rotor position, for example as illustrated inFIG. 5 and FIG. 6. A significant disadvantage of these prior art methodsis the necessity for phase current measurement circuitry, consisting ofcurrent sensing resistors, voltage amplifiers and comparators. Theseincrease controller cost and size. Due to the low amplitude voltagenature of signals used in such phase current measurements, the resultantcircuitry is also more sensitive to electrical noise and voltage driftand offset errors, which can occur due to high temperature variations inmotor control applications. These prior art methods can lead toinaccurate rotor position detections during motor start-up in demandingapplications.

Some examples of inductance variation based measurement techniques fromthe prior art employing open phase voltage measurements are disclosed inU.S. Pat. Nos. 6,344,721, 6,650,082 and US2014/0015458. It is evidentthat these techniques only employ voltage measurements at the open phasewinding during the on-time period of pulse to estimate the rotorposition, as shown in FIG. 7 of disclosure US2014/0015458.

In contrast to the prior art, the present embodiments use both theon-time and off-time open phase winding measurements in the generatedpulses to ascertain the rotor position. In an attempt to address a setof challenges in the area of sensorless BLDCM controllers, theembodiments offer several advantages, including: increased rotorposition angle detection accuracy; faster rotor position detection time;rotor position detection independent of rotor speed; insensitivity tostator phase winding inductance and resistance asymmetries in BLDCmotors.

Initial Rotor Position Detection

This section discloses the initial rotor position detection methodsdeveloped. A description of the pulse generation and on-time andoff-time phase voltage measurements for each phase coil pair combinationis presented first. This is followed by a description of novel rotorposition functions (RPF) and rotation direction functions (RDF) used tocalculate accurate rotor position and spin direction.

The key constituents of the initial rotor position detection methodsdisclosed in this section are: On-time and off-time open phase voltagemeasurement; Rotor position functions (RPF); Enhanced rotor positionfunctions (ERPF); Absolute angle rotor position calculation (θ); andRotation direction functions (RDF).

The operation flowcharts of the three different initial rotationdirection detection methods disclosed in this section are illustrated inFIG. 16, FIG. 17 and FIG. 18. For each of these, two initial rotorposition detection calculation embodiments are also disclosed, with the2nd embodiment denoted with the Δ suffix.

(a) On-time and Off-time Open Phase Voltage Measurement

Both the on-time and the off-time voltage responses are measured at theinactive phase coil winding for each of the six possible phase coil paircombination (B+/C−, C+/B−, C+/A−, A+/C−, A+/B−, B+/A−) and thenconsequently used to calculate the rotor position. This is one of thekey advantages. An example of the voltage and current waveformsgenerated in the disclosed method for the case when B+/C− phase coils(B_H and C_L power transistors in circuit diagram in FIG. 2 are active)are pulsed for a short duration resulting in a current flowing throughthe phase windings, is illustrated in FIG. 8. The on-time and off-time(Von and Voff) open phase voltage levels depend on inductances of phasewindings B and C which vary with rotor position due to RIMS variations,effectively forming a voltage divider circuit. This first step of thedisclosed initial rotor position detection is shown in the flowcharts inFIG. 16, FIG. 17 and FIG. 18, and it is the same for all three differentdetection methods presented in later sections.

(i) On-time Measurement Pulse Interval

The on-time (Ton) pulse measurement duration, shown in FIG. 8 is adaptedto the BLDC motor's electrical time constant (τ), which can be measuredoff-line or during operation. In practical BLDC motors tested, τ valueswere measured in the range between 150 μs to 1500 μs. One of therequirements for this inductance variation voltage measurement method isthat Ton<<τ. Accordingly, Ton duration in the range 20 μs-70 μs wasfound to work well in practice. This on-time pulse duration issignificantly shorter compared to other techniques which are, in turn,known to generate on-time pulse as long as 1 ms or even greater, forexample as shown in the prior art FIG. 7. The embodiments therefore havea significantly faster initial rotor position detection time.

During the on-time interval of the generated pulse, the Von measurementis taken at the open phase winding. In the example shown in FIG. 8, thiswould be performed at the A open phase winding. In practice, the mostaccurate results are obtained when this measurement is performed towardsthe end of the on-time pulse interval, for example when t>Ton/2. Thisallows the current in phase windings to reach to an appreciable leveland induce measurable voltages in the phase windings and also allows anyswitching voltage transients at the start of each pulse in the openphase windings to decay, for example as can be observed in themeasurement sequence in FIG. 9. Accurate open phase voltage measurementscan then be obtained.

In addition to the open phase voltage measurement (Von), the supplyvoltage rail (Vs) is also measured during this on-time pulse interval.This is performed to correct the open phase voltage measurements of allphase coil pair combinations for any fluctuations in the supplyvoltages, for example as shown in FIG. 10, which can occur with lowinternal resistance supply sources such as batteries. This challengedoes not appear to have been addressed in the prior art. This voltagecorrelation procedure is explained in more detail below.

(ii) Off-time Measurement Pulse Interval

After the on-time interval has elapsed the B_H and C_L power transistordevices are turned off and B_L transistor is turned on, as illustratedin the example of FIG. 8. Compared to the prior art methods which simplyturn-off both of these power transistors after the completion of on-timepulse interval, this disclosed technique has two distinct advantages: 1)Reduced power losses in the bottom phase coil (B) power transistor (B_L)as a result of bypassing the freewheeling diode which normally conductsthe inductive turn-off current; and 2) Bottom phase coil (B) voltagereference is set to the ground rail (0V) instead of the freewheelingdiode voltage drop (−Vd) allowing open phase voltage correlationcalculations to be performed to correct the open phase windingmeasurements for any supply voltage fluctuations during initial rotorposition detection, for example as shown in FIG. 10.

The off-time (Voff) voltage measurement is performed as soon as theturn-off switching transients in the open phase winding have decayedaway. In practice, this was found to typically occur around 5 μsec-15μsec after the end of on-time (Ton) period. After the completion of Voffopen phase winding voltage measurement, the bottom power transistor(B_L) is turned-off, as illustrated in FIG. 8.

During the off-time interval the current i(t) in phase coils B and Cflows through the freewheeling diode of power transistor C_H until itdecays to zero, as depicted in FIG. 8. This action also returns backsome energy to the power supply voltage source (Vs), which can benefitbattery operated applications. Since the inactive C_H transistor'sfreewheeling diode is conducting the current i(t) during this off-timeperiod, the voltage seen at the C phase winding is equal to the supplyvoltage (Vs) plus the diode voltage drop (Vd), that is Vsoff=Vs+Vd.

To correlate the measured off-time open phase voltage to the onemeasured during on-time pulse interval, the embodiment also performs avoltage measurement at the C phase winding, as shown in FIG. 8, whichsees a positive voltage (Vsoff) during this off-time interval when thefreewheeling diode in transistor C_H is conducting the current.

(iii) On-time and Off-time Measurement Pulse Interval Extensions

It should be noted that it is also possible to use the same method tomeasure the on-time (Von) and off-time (Voff) open phase voltages withrespect to the supply voltage (Vs) rail, instead of the ground (0V)voltage rail. In this case, during the off-time pulse measurementinterval, the phase coil with the positive voltage polarity is activelyconnected to the supply voltage (Vs) rail via the high-side powertransistor, by turning it on. The phase coil with the negative voltagepolarity is disconnected from the ground rail (0V) by turning-off thelow-side power transistor. This allows the decaying phase current i(t)to circulate to the ground voltage rail via the low-side powertransistor's internal freewheeling diode. To illustrate this variationin the disclosed off-time interval pulse measurement method with apractical example in FIG. 8, the positive voltage polarity phase coil(C) is instead connected to the supply voltage (Vs) rail by turning-onpower transistor C_H. The phase coil with negative voltage polarity (B)is disconnected from the ground rail (0V) by turning-off powertransistors B_L. The internal body diode of power transistor B_Lfreewheels the decaying current i(t) and clamps the voltage at phasecoil B to −Vd volts with respect to the ground rail (0V). The voltageseen at phase winding B, with respect to the supply voltage rail (Vs)which is used as the measurement reference, is equal to the supplyvoltage (Vs) plus the diode voltage drop (Vd), that is Vsoff=Vs+Vd. Withthe power transistors activated in these states, the off-time (Voff)open phase voltage measurement is then performed with respect to thesupply voltage rail (Vs). After the completion of this off-time (Voff)open phase voltage measurement, the low-side power transistor B_L isturned-off, thus completing the off-time interval measurement cycle.

As a further extension to the disclosed on-time (Von) and off-time(Voff) open phase voltage measurements, it is also possible to make theoff-time (Voff) open phase voltage measurements during the off-timepulse interval with all power transistors turned-off. This variation inthe disclosed method during the off-time pulse measurement interval,illustrated in FIG. 8, is achieved in practise by disconnecting thepositive voltage polarity phase coil (C) from the supply voltage (Vs)rail by turning-off power transistor C_H, and disconnecting the negativevoltage polarity phase coil (B) from the ground rail (0V) by turning-offpower transistors B_L. In this case, the decaying phase coil currenti(t) clamps the positive polarity phase coil (C) to the positive supplyvoltage (Vs) rail via power transistor C_H internal freewheeling diode,where for example, phase coil C voltage equals to Vs+Vd with respect toground rail (0V). The decaying phase coil current i(t) also clamps thenegative polarity phase coil (B) to the ground rail (0V) via powertransistor B_L internal freewheeling diode, where for example, phasecoil B voltage equals to −Vd with respect to the ground rail (0V). Theoff-time (Voff) open phase voltage measurement can then be made withrespect to the ground rail (0V) or supply voltage rail (Vs) as themeasurement reference point.

(b) On-time and Off-time Voltage Measurement Sequence

To determine the initial rotor position, a sequence of on-time andoff-time open phase winding and supply voltage measurementscorresponding to the six possible pairs of phase combinations isperformed first. An example sequence captured from a practical BLDCmotor is shown in FIG. 9. In this application example phase windingsB+/C−, C+/B−, C+/A−, A+/C−, A+/B−, B+/A− are pulsed by activating thepower transistor devices B_H/C_L, C_H/B_L, C_H/A_L, A_H/C_L, A_H/B_L,B_H/A_L (shown in FIG. 2) respectively. It should be noted that anyother pulse sequences with any other phase coil pair combinations canalso be used in the disclosed method to achieve the same effect, forexample a sequence such as B+/A−, A+/B−, B+/C−, C+/B−, A+/C−, C+/A−.

Since the pulse on-time durations are very short, typically in the rangebetween 20 μsec-70 μsec, no net torque is imposed on the BLDCM rotor tocause it to turn and thus the rotor remains stationary. The entiremeasurement process takes <1 ms to complete (typ. ˜600 us) which is veryshort.

(i) On-time and Off-time Open Phase Voltage Measurements

Table 1 below shows the six pairs of on-time and off-time open phasewinding voltage measurements, obtained from the measurement sequenceshown in FIG. 9.

TABLE 1 On-time and Off-time open phase voltage measurements On-timeOff-time Active Phase Open Phase Open Phase Coil Pair Voltage VoltageB+/C− VonAbc VoffAbc C+/B− VonAcb VoffAcb C+/A− VonBca VoffBca A+/C−VonBac VoffBac A+/B− VonCab VoffCab B+/A− VonCba VoffCba

For example, the notation VonAbc refers to open phase winding A on-timevoltage measurement with phase coil B connected to Vs via B_H switch andphase coil C connected to the ground via C_L switch. Similarly, thenotation VoffAbc refers to open phase winding A off-time voltagemeasurement with phase coil C freewheeling to Vs+Vd via C_H switch diodeand phase coil B connected to the ground via B_L switch.

(ii) On-time and Off-time Supply Voltage Measurements

The six pairs of supply voltage measurements during the on-time andoff-time pulse intervals shown in Table 2 are also performed during themeasurement sequence presented in FIG. 9.

TABLE 2 On-time and Off-time open phase voltage measurements On-timeOff-time Active Phase Phase Supply Phase Supply Coil Pair VoltageVoltage B+/C− Vs_BC Vsoff_BC C+/B− Vs_CB Vsoff_CB C+/A− Vs_CA Vsoff_CAA+/C− Vs_AC Vsoff_AC A+/B− Vs_AB Vsoff_AB B+/A− Vs_BA Vsoff_BA

Where, for example, the notation Vs_BC refers to on-time supply voltage(Vs) measurement with phase coil B connected to Vs via B_H switch andphase coil C connected to the ground via C_L switch. Similarly, thenotation Vsoff_BC refers to off-time supply voltage measurement (Vs+Vd)with phase coil C freewheeling to Vs+Vd voltage level via C_H switchdiode and phase coil B connected to the ground via B_L switch.

(iii) On-Time and Off-Time Voltage Measurement Correlation

In the disclosed method, the measured on-time and off-time open phasevoltages are correlated to each other for the following key reasons: 1)To scale down the off-time (Voff) open phase winding voltagemeasurements that are referenced to voltage level Vs+Vd, instead of Vsas in on-time (Von) open phase winding measurements; 2) To compensateon-time (Von) and off-time (Voff) open phase winding voltagemeasurements for any fluctuations in the power supply, as shown in FIG.10, which is commonly found in battery operated applications; 3) Therotor position detection calculations disclosed require that all of theon-time (Von) and off-time (Voff) open phase winding voltages in themeasurement sequence have the same supply voltage reference level.

Correlation of Voff to Von measurements is performed via the scalingcalculation Vs/Vsoff using their respective Vs and Vsoff supply voltagemeasurements, as shown in the following equations for each phase coilpair:VoffAbc′=VoffAbc·Vs_BC/Vsoff_BC  (1)VoffAcb′=VoffAcb·Vs_BC/Vsoff_CB  (2)VoffBca′=VoffBca·Vs_BC/Vsoff_CA  (3)VoffBac′=VoffBac·Vs_BC/Vsoff_AC  (4)VoffCab′=VoffCab·Vs_BC/Vsoff_AB  (5)VoffCba′=VoffCba·Vs_BC/Vsoff_BA  (6)

It should be noted that, in this embodiment, all Voff open phasemeasurements in the measurement sequence are correlated to the openphase measurement of the first phase coil pair. In the examplemeasurement sequence shown in FIG. 9 and FIG. 10, this is the B+/C−active phase coil pair. However, any other active phase coil pairs inthe measurement sequence could also be realized as the reference coilpair.

To prevent fluctuations in supply voltage rail (Vs) from affecting theVon and Voff open phase winding measurements in the entire measurementsequence, as shown in FIG. 10, the same voltage scaling adjustment foreach coil pair is also performed for all Von open phase windingmeasurements with the following calculations:VonAbc′=VonAbc  (7)VonAcb′=VonAcb·Vs_BC/Vs_CB  (8)VonBca′=VonBca·Vs_BC/Vs_CA  (9)VonBac′=VonBac·Vs_BC/Vs_AC  (10)VonCab′=VonCab·Vs_BC/Vs_AB  (11)VonCba′=VonCba·Vs_BC/Vs_BA  (12)

The open phase voltage correlation step is shown in initial rotorposition detection operation flowcharts in FIG. 16, FIG. 17 and FIG. 18,and it is the same for all three different detection methods disclosedin later sections.

(iv) Stator Core Demagnetization

During testing of the disclosed sensorless BLDCM controller, it wasfound that high motor currents can leave a net residual magnetic flux inthe iron stator core in BLDCM motors. This can lead to reduced accuracyand precision of the detected initial rotor positions. To address thisissue, a novel and improved measurement technique was developed thatconsists of the application of very short duration pulses before themain on-time and off-time measurement pulses, as shown in FIG. 9. Inthis example embodiment each main measurement active phase coil pair(B+/C−, C+/B−, C+/A−, A+/C−, A+/B−, B+/A−) is preceded by a shorteron-time pulse with exactly the same polarity.

Pulse durations in the range between 5 μsec-15 μsec were tested to workwell in practice. The purpose of these shorter preceding pulses is toquickly demagnetize the iron stator core in the event that it containssome net residual magnetic flux fields from a previous sensorless BLDCMoperation. The accuracy and precision of Von and Voff measurements andthus the resultant rotor position detection is improved in practicalapplication.

In time critical initial rotor position detection applications, wherethe fastest possible detection time is required, it was found that equalimprovements were also obtained by applying the shorter duration ironstator core demagnetization pulses to only every second phase coil pair(B+/C−, C+/A−, A+/B−) as shown in FIG. 10. In this embodiment the groupswith the same active phase coil pairs (B+/C− and C+/B−, C+/A− and A+/C−,A+/B− and B+/A−) are preceded by a single shorter on-time pulse (B+/C−,C+/A−, A+/B−) with same polarity as the first active coil pair in thegroup.

The disclosed short preceding pulses, which offer a performanceimprovement, are not critical to the working of the overall embodiment.Thus they can also be completely omitted from the on-time and off-timephase voltage measurements pulse sequence.

(c) Rotor Position Functions

The six pairs of correlated Von and Voff open phase winding measurementsobtained from the sequence of voltage pulses, as shown in applicationexamples in FIG. 9 and FIG. 10, are used directly in the calculations ofthe novel rotor position functions developed to determine accurate BLDCmotor angular rotor position. These rotor position functions areimportant, and address the following challenges:

1) Increased rotor position angle detection accuracy to within ±30°sectors, compared to ±60° sectors commonly disclosed in the prior artmethods, thus increasing motor start-up performance;

2) Absolute rotor position calculation to with few angular degrees usingadditional trigonometric calculations;

3) Rotor position detection independent of rotor speed, making detectionpossible at standstill or in motion;

4) Insensitivity to stator phase winding inductance and resistanceasymmetries in BLDC motors

Two embodiments used to calculate the RPFs are disclosed, with the 2ndembodiment denoted with the Δ suffix.

(i) Rotor Position Function Calculations (1st Embodiment)

According to the first embodiment, the rotor position functions (PA, PB,PC) consisting of correlated Von and Voff open phase windingmeasurements are calculated with:PA=(VonCab−VoffCab)+(VonCba−VoffCba)+(VonBca−VoffBca)+(VonBac−VoffBac)−2·(VonAbc−VoffAbc)−2·(VonAcb−VoffAcb)  (13)PB=(VonAbc−VoffAbc)+(VonAcb−VoffAcb)+(VonCab−VoffCab)+(VonCba−VoffCba)−2·(VonBca−VoffBca)−2·(VonBac−VoffBac)  (14)PC=(VonBca−VoffBca)+(VonBac−VoffBac)+(VonAbc−VoffAbc)+(VonAcb−VoffAcb)−2·(VonCab−VoffCab)−2·(VonCba−VoffCba)  (15)

An application example of the output rotor positions calculated by thesefunctions in a BLDC motor is presented in FIG. 11. As shown, thesefunctions (PA, PB, PC) have sinusoidal properties and they are shiftedapart by 120° from which accurate rotor position within ±60° sectors canbe deduced.

In addition, a set of rotor position functions (PA_30, PB_30, PC_30)shifted by +30° compared to (PA, PB, PC) are also disclosed. They areused to further improve the detected rotor position accuracy to within±30° sectors and are calculated with the following functions consistingof correlated Von and Voff measurements:PA_30=(VonCab−VoffCab)+(VonCba−VoffCba)−(VonAbc−VoffAbc)−(VonAcb−VoffAcb)  (16)PB_30=(VonAbc−VoffAbc)+(VonAcb−VoffAcb)−(VonBca−VoffBca)−(VonBac−VoffBac)  (17)PC_30=(VonBca−VoffBca)+(VonBac−VoffBac)−(VonCab−VoffCab)−(VonCba−VoffCba)  (18)

An example of the +30° shifted output rotor positions calculated bythese functions in a practical BLDC motor application is shown in FIG.12.

(ii) −30° Shifted Rotor Position Function Calculations (2nd Embodiment(Δ))

In certain challenge applications of initial rotor position detection ofBLDC motors, it was found advantageous to employ rotor positionsfunctions shifted by −30° compared to the functions (PA, PB, PC) and(PA_30, PB_30, PC_30) disclosed in the first embodiment. The reasons forthis will become more apparent below. Apart from this −30° phase shift,these rotor position functions have the same properties as the sets offunctions (PA, PB, PC) and (PA_30, PB_30, PC_30) disclosed in the firstembodiment.

According to the second embodiment of this invention, the −30° shiftedrotor position functions (PA_Δ, PB_Δ, PC_Δ) consisting of correlated Vonand Voff open phase winding measurements are calculated with:PA_Δ=(VonBca−VoffBca)+(VonBac−VoffBac)−(VonAbc−VoffAbc)−(VonAcb−VoffAcb)  (19)PB_Δ=(VonCab−VoffCab)+(VonCba−VoffCba)−(VonBca−VoffBca)−(VonBac−VoffBac)  (20)PC_Δ=(VonAbc−VoffAbc)+(VonAcb−VoffAc)−(VonCab−VoffCab)−(VonCba−VoffCba)  (21)

Similarly, according to this second embodiment, the set of rotorposition functions (PA_30_Δ, PB_30_Δ, PC_30_Δ) shifted by +30° comparedto (PA_Δ, PB_Δ, PC_Δ) are calculated with the following functionsconsisting of correlated Von and Voff measurements:PA_30_Δ=PA  (22)PB_30_Δ=PB  (23)PC_30_Δ=PC  (24)

(iii) Rotor Position Detection Implementation with RPFs

The following section presents the implementation of the disclosed rotorposition detection. The RPF calculations from the first 1st embodimentare presented. For the implementation of the 2nd embodiment, thefunction equations with the Δ suffix are used, for example PA_Δ insteadof PA. The steps used to determine the rotor position within ±30°sectors are:

1) Calculate (PA, PB, PC) RPFs using the six pairs of correlated Von andVoff open phase winding measurements as inputs.

2) Determine initial rotor position to within 60° sector by checking thesign of the RPFs, as shown in Table 3. The corresponding commutationstate number is obtained.

3) Refine rotor position to within 30° sector with (PA_30, PB_30, PC_30)RPFs corresponding to commutation state determined in step 1. The signof this RPF determines the ±30° sector within current 60° sector, asshown in Table 4.

TABLE 3 Initial rotor position estimate within 60° sector using (PA, PB,PC) RPFs Rotor PA RPF PB RPF PC RPF Position Commutation Sign Sign SignSector θ State Check Check Check  0-60° 0 PA ≥ 0 PB < 0 PC ≥ 0  60-120°1 PA ≥ 0 PB < 0 PC < 0 120-180° 2 PA ≥ 0 PB ≥ 0 PC < 0 180-240° 3 PA < 0PB ≥ 0 PC < 0 240-300° 4 PA < 0 PB ≥ 0 PC ≥ 0 300-360° 5 PA < 0 PB < 0PC ≥ 0

TABLE 4 Refined rotor position estimate within 30° sectors using (PA_30,PB_30, PC_30) RPFs Rotor RPF Position Commutation Sign Sector θ StateCheck  0-30° 0 PA_30 < 0 30-60° 0 PA_30 ≥ 0 60-90° 1 PC_30 ≥ 0  90-120°1 PC_30 < 0 120-150° 2 PB_30 < 0 150-180° 2 PB_30 ≥ 0 180-210° 3 PA_30 ≥0 210-240° 3 PA_30 < 0 240-270° 4 PC_30 < 0 270-300° 4 PC_30 ≥ 0300-330° 5 PB_30 ≥ 0 330-360° 5 PB_30 < 0

This initial rotor position detection method is also presented in theoperation flowchart shown in FIG. 16.

(d) Enhanced Rotor Position Functions

During development of the disclosed sensorless BLDCM controller, it wasfound that some BLDC motors exhibit undesirable characteristics whichmake it more difficult to detect accurate and precise rotor positionusing the rotor position function calculations disclosed in the 1stembodiment (PA, PB, PC) and (PA_30, PB_30, PC_30), and the 2ndembodiment (PA_Δ, PB_Δ, PC_Δ) and (PA_30_Δ, PB_30_Δ, PC_30_Δ). Thesenon-ideal characteristics can exist in some BLDC motor due to theirphysical construction, the level of rotor magnetic field strength andeffects such as mutual inductance.

Consequently, a set of additional initial rotor position detectionembodiments have also been developed to address this challenge. Theseconsist of a set of enhanced rotor position functions (ERPF) developedto work in conjunction with the previously disclosed RPFs that havesimilar properties.

As with RPFs, two ERPF embodiments are disclosed, with the 2ndembodiment denoted with the Δ suffix.

(i) Enhanced Rotor Position Function Calculations (1st Embodiment)

The enhanced rotor position functions (EPA0, EPC1, EPB2, EPA3, EPC4,EPB5), consisting of correlated Von and Voff open phase windingmeasurements are calculated with:EPA0=(VonCba−VoffCab)+(VonBac−VoffBca)−2·(VonAcb−VoffAbc)(300°≤θ<60°)  (25)EPC1=(VonBca−VoffBac)+(VonAbc−VoffAcb)−2·(VonCab−VoffCba)(0°≤θ<120°)  (26)EPB2=(VonAcb−VoffAbc)+(VonCba−VoffCab)−2·(VonBac−VoffBca)(60°≤θ<180°)  (27)EPA3=(VonCab−VoffCba)+(VonBca−VoffBac)−2·(VonAbc−VoffAcb)(120°≤θ<240°)  (28)EPC4=(VonBac−VoffBca)+(VonAcb−VoffAbc)−2·(VonCba−VoffCab)(180°≤θ<300°)  (29)EPB5=(VonAbc−VoffAcb)+(VonCab−VoffCba)−2·(VonBca−VoffBac)(240°≤θ<360°)  (30)

These enhanced rotor position functions are applied to each of the six60° rotor position sectors to improve the zero crossings of thecalculated rotor position functions, as shown in the practical examplein FIG. 13 and FIG. 14. With this method, the BLDCM rotor positionfunction outputs calculated with RPFs in FIG. 13 are further refinedusing EPRF calculations resulting in the output functions shown in FIG.14, where the flat regions and kinks at the zero-crossings are removed.Thus ERPFs can provide an improved and more decisive and accurate rotorposition detection of each 60° sector zero-crossing with certain BLDCmotors as tested.

In addition, a set of rotor position functions (EPA0_30, EPC1_30,EPB2_30, EPA3_30, EPC4_30, EPB5_30) shifted by +30° compared to (EPA0,EPC1, EPB2, EPA3, EPC4, EPB5) are also disclosed in this embodiment. Aswith the RPFs, they are used to further improve the detected rotorposition accuracy to within ±30° sectors and are calculated with thefollowing functions consisting of correlated Von and Voff measurements:EPA0_30=(VonCab−VoffCba)−(VonAcb−VoffAbc) (0°≤θ<60°)  (31)EPC1_30=(VonBac−VoffBca)−(VonCab−VoffCba) (60°≤θ<120°)  (32)EPB2_30=(VonAbc−VoffAcb)−(VonBac−VoffBca) (120°≤θ<180°)  (33)EPA3_30=(VonCba−VoffCab)−(VonAbc−VoffAcb) (180°≤θ<240°)  (34)EPC4_30=(VonBca−VoffBac)−(VonCba−VoffCab) (240°≤θ<300°)  (35)EPB5_30=(VonAcb−VoffAbc)−(VonBca−VoffBac) (300°≤θ<360°)  (36)

(ii) −30° Shifted Enhanced Rotor Position Function Calculations (2ndEmbodiment (Δ))

The enhanced rotor position functions (EPA0_Δ, EPC1_Δ, EPB2_Δ, EPA3_Δ,EPC4_Δ, EPB5_Δ) shifted by −30° compared to the functions (EPA0, EPC1,EPB2, EPA3, EPC4, EPB5) are calculated with the following functionsconsisting of correlated Von and Voff measurements:EPA0_Δ=(VonBca−VoffBac)−(VonAcb−VoffAbc) (300°≤θ<60°)  (37)EPC1_Δ=(VonAcb−VoffAbc)−(VonCab−VoffCba) (0°≤θ<120°)  (38)EPB2_Δ=(VonCab−VoffCba)−(VonBac−VoffBca) (60°≤θ<180°)  (39)EPA3_Δ=(VonBac−VoffBca)−(VonAbc−VoffAcb) (120°≤θ<240°)  (40)EPC4_Δ=(VonAbc−VoffAcb)−(VonCba−VoffCab) (180°≤θ<300°)  (41)EPB5_Δ=(VonCba−VoffCab)−(VonBca−VoffBac) (240°≤θ<360°)  (42)

Similarly, a set of rotor position functions (EPA0_Δ_30, EPC1_Δ_30,EPB2_Δ_30, EPA3_Δ_30, EPC4_Δ_30, EPB5_Δ_30) shifted by +30° compared to(EPA0_Δ, EPC1_Δ, EPB2_Δ, EPA3_Δ, EPC4_Δ, EPB5_Δ) are calculated with thefollowing functions consisting of correlated Von and Voff measurements:EPA0_Δ_30=EPA0(0°≤θ<60°)  (43)EPC1_Δ_30=EPC1(60°≤θ<120°)  (44)EPB2_Δ_30=EPB2(120°≤θ<180°)  (45)EPA3_Δ_30=EPA3(180°≤θ<240°)  (46)EPC4_Δ_30=EPC4(240°≤θ<300°)  (47)EPB5_Δ_30=EPB5(300°≤θ<360°)  (48)

(iii) Rotor Position Detection Implementation with RPFs and ERPFs

If improvements in the accuracy of rotor position calculations arerequired to overcome the flat regions and kinks in RPF zero-crossingthat exist in some BLDC motors, for example as shown in FIG. 13 and FIG.14, then ERPFs are employed to calculate the rotor position. The RPF andERPF calculations from the first 1st embodiment are presented in thissection. For the implementation of the 2nd embodiment, the functionequations with the Δ suffix are used, for example EPA0_Δinstead of EPA0.The steps used to determine the rotor position within ±30° sectors are:

1) Calculate (PA, PB, PC) using the 6 sets of correlated Von and Voffmeasurements as inputs.

2) Determine initial rotor position to within 60° sector by checking thesign of (PA, PB, PC) RPFs, as shown in Table 3. The correspondingcommutation state number is obtained.

3) Improve the accuracy of rotor position estimate obtained in step 2,by checking (EPA0, EPC1, EPB2, EPA3, EPC4, EPB5) ERPFs as outlined inTable 5. A refined output rotor position, θ and commutation state areobtained after this step.

4) Refine rotor position to within 30° sector with (EPA0_30, EPC1_30,EPB2_30, EPA3_30, EPC4_30, EPB5_30) ERPF corresponding to thecommutation state determined in step 3. The sign of this ERPF determinesrotor position to ±30° within current 60° sector, as shown in Table 6.

TABLE 5 Refined rotor position using (EPA0, EPC1, EPB2, EPA3, EPC4,EPB5) ERPFs Input Rotor Pos. Output Rotor Pos. Comm. ERPFs ERPF Comm.State Sector θ Comparison Sign Check State Sector θ 0  0-60° EPA0 < EPC1EPA0 < 0 5 300-360° EPA0 ≥ 0 0  0-60° 0  0-60° EPA0 ≥ EPC1 EPC1 < 0 1 60-120° EPC1 ≥ 0 0  0-60° 1  60-120° EPC1 > EPB2 EPC1 < 0 1  60-120°EPC1 ≥ 0 0  0-60° 1  60-120° EPC1 ≤ EPB2 EPB2 < 0 1  60-120° EPB2 ≥ 0 2120-180° 2 120-180° EPB2 < EPA3 EPB2 < 0 1  60-120° EPB2 ≥ 0 2 120-180°2 120-180° EPB2 ≥ EPA3 EPA3 < 0 3 180-240° EPA3 ≥ 0 2 120-180° 3180-240° EPA3 > EPC4 EPA3 < 0 3 180-240° EPA3 ≥ 0 2 120-180° 3 180-240°EPA3 ≤ EPC4 EPC4 < 0 3 180-240° EPC4 ≥ 0 4 240-300° 4 240-300° EPC4 <EPB5 EPC4 < 0 3 180-240° EPC4 ≥ 0 4 240-300° 4 240-300° EPC4 ≥ EPB5 EPB5< 0 5 300-360° EPB5 ≥ 0 4 240-300° 5 300-360° EPB5 > EPA0 EPB5 < 0 5300-360° EPB5 ≥ 0 4 240-300° 5 300-360° EPB5 ≤ EPA0 EPA0 < 0 5 300-360°EPA0 ≥ 0 0  0-60°

TABLE 6 Refined rotor position estimate within 30° sectors using(EPA0_30, EPC1_30, EPB2_30, EPA3_30, EPC4_30, EPB5_30) ERPFs Rotor ERPFPosition Commutation Sign Sector θ State Check  0-30° 0 EPA0_30 < 030-60° 0 EPA0_30 ≥ 0 60-90° 1 EPC1_30 ≥ 0  90-120° 1 EPC1_30 < 0120-150° 2 EPB2_30 < 0 150-180° 2 EPB2_30 ≥ 0 180-210° 3 EPA3_30 ≥ 0210-240° 3 EPA3_30 < 0 240-270° 4 EPC4_30 < 0 270-300° 4 EPC4_30 ≥ 0300-330° 5 EPB5_30 ≥ 0 330-360° 5 EPB5_30 < 0

This initial rotor position detection method employing both RPF and ERPFcalculations is presented in the operation flowchart shown in FIG. 17.

(iv) Enhanced Rotor Position Functions Extensions

In application with certain types of BLDC motors, such as internalpermanent magnet (IPM) motors, it was found that the calculation orderof the enhanced rotor position functions (EPA0, EPC1, EPB2, EPA3, EPC4,EPB5), and +30° shifted functions (EPA0_30, EPC1_30, EPB2_30, EPA3_30,EPC4_30, EPB5_30) of the 1st and 2nd (Δ) embodiments had to be modified,in order to obtain the same effect. This is achieved by swapping theenhanced rotor position function calculations with the same phase coilpairs (eg. EPAx, EPBx, EPCx) as outlined below:EPA0x=EPA3x(0°≤θ<60°)EPC1x=EPC4x(60°≤θ<120°)EPB2x=EPB5x(120°≤θ<180°)EPA3x=EPA0x(180°≤θ<240°)EPC4x=EPC1x(240°≤θ<300°)EPB5x=EPB2x(300°≤θ<360°)

Where: x={“,_30,_Δ,_Δ_30}

Thus, this calculation swap applies to all of the following disclosedenhanced rotor position function calculations, eg. normal (no shift) andshifted by +30°, of the 1st and 2nd (Δ) embodiments:

-   (EPA0, EPC1, EPB2, EPA3, EPC4, EPB5)|-   (EPA0_30, EPC1_30, EPB2_30, EPA3_30, EPC4_30, EPB5_30)-   (EPA0_Δ, EPC1_Δ, EPB2_Δ, EPA3_Δ, EPC4_Δ, EPB5_Δ)-   (EPA0_Δ_30, EPC1_Δ_30, EPB2_Δ_30, EPA3_Δ_30, EPC4_Δ_30, EPB5_Δ_30)

(e) Absolute Rotor Position Calculation

Accurate rotor position detection within ±30° sectors is possible withsimple interpretations of the zero-crossing points and intersectionpoints of the rotor position functions, as disclosed in the previoussections. This embodiment presents a method employing trigonometriccalculations to improve the angular resolution to within a few degreesof the actual electrical rotor position. The complex vector space is anexample of such a method that projects (PA, PB, PC) RPF voltagemagnitudes from which the resultant rotor position vector (PR) iscalculated with the following equation:PR=√{square root over( )}[(PA−PB/2−PC/2)²+¾·(PB−PC)²]·exp{j·tan⁻¹[√{square root over( )}(3/2)·(PB−PC)/(PA−PB/2−PC/2)]}  (49)

The absolute rotor position (θ) is then given by:θ=tan⁻¹[√{square root over ( )}(3/2)·(PB−PC)/(PA−PB/2−PC/2)]  (50)

For the implementation of the 2nd embodiment of the disclosedcontroller, the function equations with the Δ suffix are used, forexample PA_Δ instead of PA. FIG. 15 shows the estimated absolute rotorposition angle (θ) using the BLDC motor with (PA, PB, PC) RPFs presentedin FIG. 11. The implementation of this rotor position calculation ispresented in the operation flowchart shown in FIG. 18.

(f) Rotation Direction Functions

When starting with a BLDC motor in motion, the forward or reverse rotorspin direction is determined with a set of developed rotation directionfunctions (RDF), which are calculated using correlated off-time (Voff)open phase winding measurements. These disclosed rotation directionfunctions evaluate to either a positive or negative value depending onthe rotor spin direction. As with RPFs and ERPFs, two embodiments aredisclosed, with the 2nd embodiment denoted with the Δ suffix. It shouldbe noted that it is equally possible to calculate the rotor spindirection with the same equations using correlated on-time (Von) openphase measurements, the only difference being that the signs of theoutput functions have the opposite value

(i) Rotor Direction Function Calculations (1st Embodiment)

The rotation direction functions (RA, RB, RC) are calculated with thefollowing equations consisting of correlated Voff measurements:RA=(VoffAbc+VoffAcb)−(VoffCab+VoffCba)  (51)RB=(VoffBca+VoffBac)−(VoffAbc+VoffAcb)  (52)RC=(VoffCab+VoffCba)−(VoffBca+VoffBac)  (53)

(ii) −30° Shifted Rotor Direction Function Calculations (2nd Embodiment(Δ))

According to the second embodiment, the rotation direction functions(RA_Δ, RB_Δ, RC_Δ) shifted by −30° compared to the functions (RA, RB,RC) of the first embodiment are calculated with the following equationsconsisting of correlated Voff measurements:RA_Δ=2·(VoffAbc+VoffAcb)−(VoffCab+VoffCba)−(VoffBca+VoffBac)  (54)RB_Δ=2·(VoffBca+VoffBac)−(VoffAbc+VoffAcb)−(VoffCab+VoffCba)  (55)RC_Δ=2·(VoffCab+VoffCba)−(VoffBca+VoffBac)−(VoffAbc+VoffAcb)  (56)

(iii) Rotation Direction Detection Implementation

At start-up, rotation direction of a BLDCM in motion is determined bycalculating the disclosed (RA, RB, RC) RDFs, which evaluate to apositive or negative value depending on direction of rotation. Thisdetection method is implemented during the initial rotor positionoperation as shown in the flowcharts in FIG. 16, FIG. 17 and FIG. 18,for the three rotor position detection methods employing RPFs, RPFs andERPFs, and absolute angle (θ) calculations respectively.

For the implementation of the 2nd embodiment, the function equationswith the Δ suffix are used, for example RA_Δ instead of RA. The stepsrequired to determine rotation direction are:

1. Calculate (RA, RB, RC) RDFs corresponding to commutation statedetermined during rotor position detection with RPFs and EPRFs. The signof the RDF output determines forward or reverse rotation direction asshown in Table 7.

TABLE 7 Rotation direction calculation with (RA, RB, RC) RDFs RotorPosition Commutation Forward Rotation Reverse Rotation Sector θ StateRDF Sign Check RDF Sign Check  0-60° 0 RA > 0 RA < 0  60-120° 1 RC < 0RC > 0 120-180° 2 RB > 0 RB < 0 180-240° 3 RA < 0 RA > 0 240-300° 4 RC >0 RC < 0 300-360° 5 RB < 0 RB > 0

(g) Initial Rotor Position Detection Extensions

The disclosed initial rotor position detection method uses on-time andoff-time open phase voltage measurements to detect inductance variationsin BLDC motor phase coils. In practice, it is also possible to applythese disclosed methods to on-time and off-time inductance variationmeasurements obtained from phase current amplitude and rise timemeasurements in order to ascertain a BLDC motor's rotor position.

Zero to Low Speed Sensorless BLDCM Operation

The initial rotor position detection methods disclosed in previoussections provide accurate and precise starting rotor positioninformation. To successfully drive a BLDC motor from standstill to highspeed, a reliable sensorless operation in the zero to low speed range isrequired. This section discloses the RIMS inductance variation basedcommutation point functions (CPF) developed to provide accuratesensorless brushless commutation at zero and low motor speeds. They arecombined with the previously disclosed rotor position functions (RPF,ERPF) and rotation direction functions (RDF) to deliver a highly robustsensorless operation at zero and low motor speeds in the presence ofexternal load disturbances and with reversed rotor momentums.

A PWM phase current control method consisting of three PWM timeintervals is also disclosed. It allows effective injection of on-timeand off-time open phase voltage measurement pulses required for the RIMSbased commutation point detection. This PWM method is combined with aquasi Field Oriented Control (QFOC) algorithm developed to maximizeoutput torque during 60° step sensorless operation.

When motor speed is sufficiently high, sensorless operation switchesover to the low to high speed sensorless commutation technique presentedin the next section, as depicted in FIG. 1.

The key parts of the disclosed zero to low speed sensorless BLDCMoperation are:

-   -   PWM phase current control using three intervals (PWMT1-PWMT3)    -   Commutation point detection functions (CPF)    -   Rotor position and rotation direction functions (RPF, ERPF, RDF)    -   60° step sensorless commutation    -   Quasi field oriented control (QFOC)    -   CPFmax measurement used in rotor magnetic field strength and        motor temperature measurement

The operational flowchart of the disclosed zero to low speed sensorlessBLDCM controller operation is illustrated in FIG. 25. As in initialrotor position detection, two zero to low speed controller embodimentsare disclosed, with the 2nd embodiment denoted with the Δ suffix.

(a) PWM Phase Current Control

The zero to low speed sensorless method of operation disclosed requiresthat the BLDCM phase driving currents are reduced to zero, asillustrated in FIG. 19, before injecting the on-time and off-timemeasurement pulses used in commutation point and rotation directiondetection. This three interval PWM method is important to the operationof the disclosed controller because it prevents any residual currentsfrom flowing through the inactive phase coils during the on-time andoff-time measurements and thus affecting the results. It is evident thatthe disclosed method of combining rotor position measurement pulses withthe stream of PWM motor phase currents, as shown in FIG. 20 and FIG. 21,is not common in the prior art. This method provides highly accurate androbust rotor position detection with reduced motor torque. Withreference to FIG. 19, the disclosed PWM phase current control methodconsists of three distinct PWM intervals:

1. PWM T1: on-time phase current interval (T1), where the active phasewindings (B+/C−) are connected to the supply (Vs) via the high-sidepower transistor (B_H) and to the ground (0V) rail via the low-sidepower transistor (C_L). A quasi FOC method, as described in latersection of this disclosure, is also integrated to increase the BLDCMdriving torque by maintaining a constant 90° torque angle between theBLDCM rotor and stator.

2. PWM T2: first off-time interval (T2) with slow phase current falltime, where both of the active phase coils (B and C) are connected tothe ground (0V) rail via the low-side power transistors (B_L and C_L).

3. PWM T3: second off-time interval (T3) with fast phase current falltime down to zero, where only the B phase coil is actively connected tothe ground (0V) rail via the low-side power transistor (B_L). Theinactive high-side phase coil (C) is connected to the power supply rail(Vs) via the turn-off current conducted by the freewheeling diode of thehigh-side transistor (C_H), clipping the phase C voltage to Vs+Vd. Theenergy from this turn-off current is returned back to the power supply.

Together these three PWM interval durations control the amplitude of thedriving current which can be set depending on the BLDCM application. Thecontrol of PWM T1, PWM T2 and PWM T3 interval durations is not limitedto any particular realization. For example, these PWM interval durationscan be pre-calculated and stored in a look-up table in the controllermemory, say to perform a simple open loop BLDCM motor speed control, orthey can be calculated in real time to perform torque control or toachieve any other BLDCM controller driving optimization. An example of asimple method of PWM control, which has been tested to work well inpractise, can be realized by setting the PWM T2 duration to zero andregulating the PWM T1 duration from 0% to 100% in order to control thelevel of the motor driving current. The PWM T1, PWM T2 and PWM T3intervals of the disclosed zero to low speed sensorless method ofoperation are generated in the step shown in the operation flowchart inFIG. 25.

(b) On-time and Off-time Open Phase and Supply Voltage Measurements

In this disclosure both the on-time and the off-time open phase voltagemeasurements are used to determine accurate sensorless operationcommutation points using the developed commutation points functions. Thesame measurements are also used to determine the rotation direction of aBLDC motor. These on-time and off-time open phase voltage measurementsare an important part of the zero to low speed sensorless BLDCMcontroller operation.

As disclosed previously, the on-time and off-time phase supply voltagesare also measured during this step to correlate the Von and Voffmeasurements and address the challenge of controller sensitivity topower supply voltage fluctuations. These steps in the zero to low speedcontroller operation are shown in the flowchart in FIG. 25.

(i) On-time and Off-time Voltage Measurement (1st Embodiment)

The same method of on-time and off-time open phase voltage measurement,as illustrated in FIG. 8 and disclosed previously in the initial rotorposition detection, is also used during the zero to low speed sensorlessBLDCM operation.

In this 1st controller embodiment, these on-time and off-time phasemeasurement pulses are inserted after the PWM (PWM T1, PWM T2, PWM T3)phase current control pulses, as shown in a practical BLDCM operation inFIG. 20. From these up to four pairs of on-time and off-time phasevoltage measurements are obtained:

TABLE 8 On-time and Off-time open phase and supply voltage measurementsduring zero to low speed sensorless BLDCM controller in the 1stembodiment On-time Off-time On-time Off-time Phase Phase Open Phase OpenPhase Supply Supply Voltage Voltage Voltage Voltage Von0 Voff0 Vs0Vsoff0 Von1 Voff1 Vs1 Vsoff1 Von2 Voff2 Vs2 Vsoff2 Von3 Voff3 Vs3 Vsoff3

The Von measurements are next correlated to the first measurement (Von0)with following calculations:Von0′=Von0  (57)Von1′=Von1·Vs0/Vs1  (58)Von2′=Von2·Vs0/Vs2  (59)Von3′=Von3·Vs0/Vs3  (60)

Similarly, the Voff measurements are correlated to the first measurement(Voff0) with following calculations:Voff0′=Voff0·Vs0/Vsoff0  (61)Voff1′=Von1·Vs0/Vsoff1  (62)Voff2′=Von2·Vs0/Vsoff2  (63)Voff3′=Von3·Vs0/Vsoff3  (64)

These correlated Von and Voff measurements are used in calculations ofcommutation point detection functions and rotation direction detectionfunctions of the 1st embodiment of this invention, which are disclosedin the proceeding sections.

(ii) On-Time and Off-Time Voltage Measurement (2nd Embodiment (Δ))

In the 2nd controller embodiment up to six pairs of on-time and off-timephase measurement pulses are inserted after the PWM (PWM T1, PWM T2, PWMT3) phase current control pulses, as shown in a practical BLDCMoperation in FIG. 21. The following six pairs of on-time and off-timephase voltage measurements are obtained:

TABLE 9 On-time and Off-time open phase and supply voltage measurementsduring zero to low speed sensorless BLDCM controller in the 2ndembodiment (Δ). On-time Off-time On-time Off-time Phase Phase Open PhaseOpen Phase Supply Supply Voltage Voltage Voltage Voltage Von0 Voff0 Vs0Vsoff0 Von1 Voff1 Vs1 Vsoff1 Von2 Voff2 Vs2 Vsoff2 Von3 Voff3 Vs3 Vsoff3Von4 Voff4 Vs4 Vsoff4 Von5 Voff5 Vs5 Vsoff5The Von measurements are next correlated to the first measurement (Von0)with following calculations:Von0′=Von0  (65)Von1′=Von1·Vs0/Vs1  (66)Von2′=Von2·Vs0/Vs2  (67)Von3′=Von3·Vs0/Vs3  (68)Von4′=Von4·Vs0/Vs4  (69)Von5′=Von5·Vs0/Vs5  (70)

Similarly, the Voff measurements are correlated to the first measurement(Von0) with following calculations:Voff0′=Voff0·Vs0/Vsoff0  (71)Voff1′=Von1·Vs0/Vsoff1  (72)Voff2′=Von2·Vs0/Vsoff2  (73)Voff3′=Von3·Vs0/Vsoff3  (74)Voff4′=Von4·Vs0/Vsoff4  (75)Voff5′=Von5·Vs0/Vsoff5  (76)

These correlated Von and Voff measurements are used in calculations ofcommutation point detection functions and rotation direction detectionfunctions, in the 2nd embodiment of this invention, denoted with the Δsuffix, which are disclosed in the proceeding sections.

(c) Commutation Point Detection

This section discloses the developed commutation point functions (CPF),derived using the RIMS variation detection methods, from which sixrobust 60° step sensorless brushless commutation intervals are obtained.It is evident that BLDC motors are available in a variety of mechanicaland winding configurations and as such they can have different RIMSvariations properties. Consequently, two CPF detection embodiments aredisclosed to cater for the differences in BLDC motors, with each havinga further set of CPF detection method variations to address thechallenge of sensorless controller operation with a broader range ofBLDC motor applications. The required Von and Voff open phase windingmeasurements for CPF calculations are integrated into the PWM cycle ofthe zero to low speed sensorless BLDCM control method as shown in FIG.20 and FIG. 21, for the 1st and 2nd embodiment (Δ) of this inventionrespectively. The disclosed commutation point detection method steps areillustrated in the operation flowchart in FIG. 25.

(i) Commutation Point Functions Using Von and Voff Measurements (1stEmbodiment)

In this first BLDCM controller embodiment, the correlated Von0 and Voff0open phase measurements, obtained using the methods disclosed previouslyand as shown in FIG. 20, are used to derive the commutation points foreach 60° commutation interval with the following calculations:CPF0_Von_Voff=VoffCab−VonCab(0°≤θ<60°)  (77)CPF1_Von_Voff=VonBac−VoffBac(60°≤θ<120°)  (78)CPF2_Von_Voff=VoffAbc−VonAbc(120°≤θ<180°)  (79)CPF3_Von_Voff=VonCba−VoffCba(180°≤θ<240°)  (80)CPF4_Von_Voff=VoffBca−VonBca(240°≤θ<300°)  (81)CPF5_Von_Voff=VonAcb−VoffAcb(300°≤θ<360°)  (82)

A practical example of correlated Von and Voff open phase voltagesmeasured in a BLDC motor is shown in FIG. 22 for one BLDCM electricalrevolution (0°-360°). From these measurements decisive commutationpoints with sharp zero-crossings are calculated using the disclosed CPFcalculations, as shown in FIG. 23 for one electrical revolution. Thecommutation points are detected when the CPFs cross the zero voltagelevel, that is CPF≤0.

This method of commutation point detection requires only the measurementof the first pulse shown in FIG. 20, containing the Von0 and Voff0measurement. The other three measurement pulses containing Von1-3 andVoff1-3 measurements are inserted into the PWM stream only after acommutation point has been detected (CPF≤0) in order to determinedirection of rotation using the RDF calculations. This will becomeapparent in the next section.

(ii) Commutation Point Functions Using Von and Von Measurements (1stEmbodiment)

In this first BLDCM controller embodiment, the correlated Von0 and Von1open phase measurements, obtained using the methods disclosed previouslyand as shown in FIG. 20, are used to derive the commutation points foreach 60° commutation interval with the following calculations:CPF0_Von_Von=VonCba−VonCab(0°≤θ<60°)  (83)CPF1_Von_Von=VonBac−VonBca(60°≤θ<120°)  (84)CPF2_Von_Von=VonAcb−VonAbc(120°≤θ<180°)  (85)CPF3_Von_Von=VonCba−VonCab(180°≤θ<240°)  (86)CPF4_Von_Von=VonBac−VonBca(240°≤θ<300°)  (87)CPF5_Von_Von=VonAcb−VonAbc(300°≤θ<360°)  (88)

The commutation points are detected when the CPFs cross the zero voltagelevel (CPF≤0). This method requires two measurement pulses containingthe Von0, Voff0 and Von1 and Voff1 measurement pairs, as shown in FIG.20. The other two measurement pulses containing Von2-3 and Voff2-3measurements are inserted into the PWM stream only after a commutationpoint has been detected (CPF≤0) and are used to determine direction ofrotation using the RDF calculations.

(iii) Commutation Point Functions Using Von and Voff Measurements (2ndEmbodiment (Δ))

During development it was found that with certain BLDCMs, such as deltawinding configuration, it was not possible to obtain accuratecommutation points using the CPFs (CPFX_Von_Voff, CPFX_Von_Von)disclosed in the first embodiment. In order to address the challenge ofcontroller operation with the broadest possible range of BLDC motorapplications, a further set of CPFs using combinations of Von and Voffopen phase voltage measurements were developed. These work inconjunctions with the previously disclosed RPF and RDF equations of the2nd embodiment, denoted with the Δ suffix.

In this second BLDCM controller embodiment, the correlated Von0 andVoff0 open phase measurements, obtained using the methods disclosedpreviously and as shown in FIG. 21, are used to derive the disclosedcommutation points for each 60° commutation interval with the followingcalculations:CPF0_Von_Voff_Δ=VoffBac−VonBac(0°≤θ<60°)  (89)CPF1_Von_Voff_Δ=VonAbc−VoffAbc(60°≤θ<120°)  (90)CPF2_Von_Voff_Δ=VoffCba−VonCba(120°≤θ<180°)  (91)CPF3_Von_Voff_Δ=VonBca−VoffBca(180°≤θ<240°)  (92)CPF4_Von_Voff_Δ=VoffAcb−VonAcb(240°≤θ<300°)  (93)CPF5_Von_Voff_Δ=VonCab−VoffCab(300°≤θ<360°)  (94)

The commutation points are detected when the CPFs cross the zero voltagelevel (CPF≤0). This method of commutation point detection requires onlythe first measurement pulse containing the Von0 and Voff0 measurement,as shown in FIG. 21. The other five measurement pulses containing Von1-5and Voff1-5 measurements are inserted into the PWM stream only after acommutation point has been detected (CPF≤0) in order to determinedirection of rotation using the RDF calculations of the 2nd embodiment(Δ) of this invention.

(iv) Commutation Point Functions Using Von and Von Measurements (2ndEmbodiment (Δ))

In this second BLDCM controller embodiment, the correlated Von0 and Von1open phase measurements, obtained using the methods disclosed previouslyand as shown in FIG. 21, are used to derive the commutation points foreach 60° commutation interval with the following calculations:CPF0_Von_Von_Δ=VonBca−VonBac(0°≤θ<60°)  (95)CPF1_Von_Von_Δ=VonAbc−VonAcb(60°≤θ<120°)  (96)CPF2_Von_Von_Δ=VonCab−VonCba(120°≤θ<180°)  (97)CPF3_Von_Von_Δ=VonBca−VonBac(180°≤θ<240°)  (98)CPF4_Von_Von_Δ=VonAbc−VonAcb(240°≤θ<300°)  (99)CPF5_Von_Von_Δ=VonCab−VonCba(300°≤θ<360°)  (100)

The commutation points are detected when the CPFs cross the zero voltagelevel (CPF≤0). This method requires two measurement pulses containingthe Von0, Voff0 and Von1 and Voff1 measurement pairs, as shown in FIG.21. The other four measurement pulses containing Von2-5 and Voff2-5measurements are inserted into the PWM stream only after a commutationpoint has been detected (CPF≤0) and are used to determine direction ofrotation using the RDF calculations of the 2nd embodiment (Δ) of thisinvention.

(v) Commutation Point Function Detection Extensions

1. CPFs Obtained using other Combinations of Correlated Von and VoffMeasurements

The commutation point detection methods presented in the 1st and 2nd (Δ)controller embodiments are not only limited to the four disclosed CPFs(CPFX_Von_Voff, CPFX_Von_Von, CPFX_Von_Voff_Δ, CPFX_Von_Von_Δ) whichwere found to work with a broad range of BLDC motors in practice. Anyother combinations of correlated Von and Voff open phase winding voltagemeasurements can also be used with the disclosed method to obtainaccurate commutation points to cater for special BLDC motorapplications, for example using Von and Voff measurement combinations ofthe form:VonXxx−VoffXxxVoffXxx−VoffXxxVonXxx−VonXxx

In practice, it was found that the selection of the most suitable CPFsis dependent on the characteristics of the Von and Voff curves measuredin a BLDC motor, for example as shown in FIG. 22. This can be performedas a controller optimization step with off-line measurements. Thus withthe careful selection of Von and Voff measurements, it was found that itis possible to obtain CPFs with sharp zero-crossing points for anypractical BLDC motor.

2. CPFs Obtained from Von or Voff Measurements in Consecutive PWM T1-T3Cycles

Furthermore, as an extension to the disclosed commutation pointdetection methods of the 1^(st) and 2^(nd) embodiments, which use Vonand Von measurements (CPFX_Von_Von) in a single PWM cycle, it is inpractice also possible to combine Von and Von measurements from twoconsecutive PWM cycles for use in CPF calculations, as shown in FIG. 24.In this practical example CPFs are calculated with:CPFX_Von_Von[1]=Von[1]−Von[0]CPFX_Von_Von[2]=Von[2]−Von[1]CPFX_Von_Von[3]=Von[3]−Von[2]

During commutation point detection with Von and Von measurements thishas the advantage of reducing the number of required measurement pulsesfrom two to one in each PWM T1-T3 cycle, which is then equivalent to thesingle pulse measurement method in the disclosed CPF calculationemploying Von and Voff measurements (CPFX_Von_Voff). The same method canalso be applied to CPFs obtained using only Voff measurements.

3. Commutation Points Obtained from Absolute Rotor Position (θ)Calculations

As a further variation to the disclosed commutation point detectionmethods for both the 1^(st) and 2^(nd) (Δ) embodiments, it is inpractise also possible to calculate accurate commutation points forreliable sensorless brushless motor operation by using rotor positioninformation obtained from the previously disclosed method involving thecalculation of absolute rotor position (θ) in equation (50). Asillustrated in the operation flowchart shown in FIG. 18, this method ofrotor position (θ) detection involves the calculation of rotor positionfunctions PA, PB and PC, by generating six pairs of correlated on-time(VonXxx) and off-time (VoffXxx) open phase measurements, which areinserted after the PWM T1-T3 cycle, as shown in the practical example inFIG. 21.

The necessary commutation points (CPF0-5) are then obtained directlyfrom the calculated absolute rotor position, by checking the value of θ:CPF0:θ>=60°CPF1:θ>=120°CPF2:θ>=180°CPF3:θ>=240°CPF4:θ>=300°CPF5:θ>=360°

(d) Rotation Direction Detection

To address the challenge of robust sensorless BLDCM controller operationat and near zero speeds and in the presence of external loaddisturbances and with reversed rotor momentum, a method for determiningthe rotation direction during the zero to low speed sensorless BLDCMoperation is disclosed in this section. The rotation detection employsthe calculation of the RPFs, ERPFs and RDFs, presented previously in theinitial rotor position detection method disclosure of this controllerinvention.

Two rotation direction calculation embodiments are also disclosed, withthe 2^(nd) embodiment denoted with the Δ suffix. For the implementationof the 2^(nd) embodiment, the function equations with the Δ suffix areused, for example RA_Δ instead of RA.

(i) Von and Voff Measurement

The required Von and Voff open phase winding measurements for rotationdirection calculation are inserted after the completion of the PWMT1-PWM T3 stream, as shown in FIG. 20 for the 1st embodiment, and FIG.21 for the 2nd embodiment (Δ) of this invention, only after acommutation point has been detected (CPF≤0). Thus during the zero to lowspeed sensorless BLDCM control method, the RDF calculation is performedonly once for each 60° step commutation state in order to check thedirection of rotation. This procedure is also illustrated in theoperation flowchart in FIG. 25.

(ii) Rotation Direction Detection with RDFs and RPFs

The rotation direction detection truth table utilizing the RPF and RDFcalculations for all six commutation intervals (0-360°) duringsensorless operation is shown in Table 10. For example, if duringforward operation forward rotation is detected, then the commutationstate is incremented. Conversely, if reverse rotation is detected thenthe commutation state is decreased. This procedure is summarized in theoperation flowchart in FIG. 25. It is valid for any of the CPF detectionmethods disclosed previously.

TABLE 10 Rotation direction detection during zero to low speedsensorless BLDCM operation with RDFs (RA, RB, RC) and RPFs (PA_30,PB_30, PC_30) Rotor Commu- Position tation Forward Rotation ReverseRotation Sector θ State Detection Condition Detection Condition  0-60° 0RA ≥ 0 ∥ PA_30 ≥ 0 !(RA ≥ 0 ∥ PA_30 ≥ 0)  60-120° 1 RC ≤ 0 ∥ PC_30 ≤ 0!(RC ≤ 0 ∥ PC_30 ≤ 0) 120-180° 2 RB ≥ 0 ∥ PB_30 ≥ 0 !(RB ≥ 0 ∥ PB_30 ≥0) 180-240° 3 RA ≤ 0 ∥ PA_30 ≤ 0 !(RA ≤ 0 ∥ PA_30 ≤ 0) 240-300° 4 RC ≥ 0∥ PC_30 ≥ 0 !(RC ≥ 0 ∥ PC_30 ≥ 0) 300-360° 5 RB ≤ 0 ∥ PB_30 ≤ 0 !(RB ≤ 0∥ PB_30 ≤ 0)

(iii) Rotation Direction Detection with RDFs and ERPFs

The rotation direction detection truth table utilizing the ERPF and RDFcalculations for all six commutation intervals (0-360°) duringsensorless operation is shown in Table 11. It is valid for any of theCPF detection methods. The operation procedure is the same as with theRPF calculations, as shown in the flowchart in FIG. 25.

TABLE 11 Rotation direction detection during zero to low speedsensorless BLDCM operation with RDFs (RA, RB, RC) and ERPFs (EPA0_30,EPC1_30, EPB2_30, EPA3_30, EPC4_30, EPB5_30) Rotor Position CommutationForward Rotation Reverse Rotation Sector θ State Detection ConditionDetection Condition  0-60° 0 RA ≥ 0 ∥ EPA0_30 ≥ 0 !(RA ≥ 0 ∥ EPA0_30 ≥0)  60-120° 1 RC ≤ 0 ∥ EPC1_30 ≤ 0 !(RC ≤ 0 ∥ EPC1_30 ≤ 0) 120-180° 2 RB≥ 0 ∥ EPB2_30 ≥ 0 !(RB ≥ 0 ∥ EPB2_30 ≥ 0) 180-240° 3 RA ≤ 0 ∥ EPA3_30 ≤0 !(RA ≤ 0 ∥ EPA3_30 ≤ 0) 240-300° 4 RC ≥ 0 ∥ EPC4_30 ≥ 0 !(RC ≥ 0 ∥EPC4_30 ≥ 0) 300-360° 5 RB ≤ 0 ∥ EPB5_30 ≤ 0 !(RB ≤ 0 ∥ EPB5_30 ≤ 0)

(iv) Rotation Direction Detection Extensions

Depending on the BLDCM application, the disclosed forward/reverserotation direction detection check can also be implemented using onlyRDFs (RA, RB, RC) calculations or only RPFs (PA_30, PB_30, PC_30)/ERPFs(EPA0_30, EPC1_30, EPB2_30, EPA3_30, EPC4_30, EPB5_30) calculations inorder to reduce controller computation complexity.

Furthermore, it is also possible to obtain accurate rotation directioninformation by utilizing the absolute rotor position (θ) calculationdisclosed previously in equation (50). This requires the six pairs ofcorrelated on-time (VonXxx) and off-time (VoffXxx) open phasemeasurements, as shown in the practical example in FIG. 21, and can becalculated after each PWM T1-T3 cycle or after a new commutation pointhas been detected. Assuming that a forward mode of operation results inincreasing rotor position angle (θ), the rotation direction can bedetermined by comparing the values of consecutive absolute rotorposition (θ) calculations:Forward Rotation: θ[n+1]>θ[n]Reverse Rotation: θ[n+1]<θ[n]

(v) Rotation Direction Detection Extensions Using Enhanced RotorPosition Functions

In application with certain types of BLDC motors, such internalpermanent magnet (IPM) motors, it was found that the calculation orderof the +30° shifted enhanced rotor position functions (EPA0_30, EPC1_30,EPB2_30, EPA3_30, EPC4_30, EPB5_30) for both the 1st and 2nd (Δ)embodiments had to be modified, in order to obtain the same effect. Thisis achieved by swapping the enhanced rotor position functioncalculations with the same phase coil pairs (eg. EPAx_30, EPBx_30,EPCx_30) as outlined below:EPA0x_30=EPA3x_30(0°≤θ<60°)EPC1x_30=EPC4x_30(60°≤θ<120°)EPB2x_30=EPB5x_30(120°≤θ<180°)EPA3x_30=EPA0x_30(180°≤θ<240°)EPC4x_30=EPC1x_30(240°≤θ<300°)EPB5x_30=EPB2x_30(300°≤θ<360°)

Where: x={“,_Δ}

Thus, this calculation swap applies to all of the following disclosedenhanced rotor position function calculations shifted by +30°, of the1st and 2nd (Δ) embodiments:

-   -   (EPA0_30, EPC1_30, EPB2_30, EPA3_30, EPC4_30, EPB5_30)    -   (EPA0_Δ_30, EPC1_Δ_30, EPB2_Δ_30, EPA3_Δ_30, EPC4_Δ_30,        EPB5_Δ_30)

(e) Sensorless BLDCM Commutation

The disclosed sensorless commutation point detection methods deliverdecisive and robust commutation points to control the BLDCM statormagnetic field in 60° steps. The strength of the stator magnetic fieldis determined by the magnitude of the BLDCM phase currents, which areregulated with the disclosed PWM method consisting of three distinctintervals (PWM T1, PWM T2, PWM T3). This step is illustrated inoperation flowchart in FIG. 25. The resultant stator magnetic fieldinteracts with the magnetic field in the permanent magnet rotor,generating a torque on the rotor axis and forcing it to turn.

(i) Sensorless Commutation (1st Embodiment)

The active phase coils in each commutation state during PWM T1, PWM T2and PWM T3 intervals in the 1st embodiment of this invention aresummarized in Table 12, Table 13, Table 14 respectively. Thecorresponding commutation point function detection and the phase windingpower transistor switching sequence for each of the six commutationsteps is shown in FIG. 26.

TABLE 12 PWM T1 interval phase coil switching states in the 1stembodiment Rotor Position Commutation Top Active Bottom Active Sector θState Phase Coil Phase Coil  0-60° 0 A+ C−  60-120° 1 B+ C− 120-180° 2B+ A− 180-240° 3 C+ A− 240-300° 4 C+ B− 300-360° 5 A+ B−

TABLE 13 PWM T2 interval phase coil switching states in the 1^(st)embodiment Rotor Position Commutation Top Active Bottom Active Sector θState Phase Coil Phase Coil  0-60° 0 — C−, A−  60-120° 1 — C−, B−120-180° 2 — A−, B− 180-240° 3 — A−, C− 240-300° 4 — B−, C− 300-360° 5 —B−, A−

TABLE 14 PWM T3 interval phase coil switching states in the 1stembodiment Rotor Position Commutation Top Active Bottom Active Sector θState Phase Coil Phase Coil  0-60° 0 — A−  60-120° 1 — B− 120-180° 2 —B− 180-240° 3 — C− 240-300° 4 — C− 300-360° 5 — A−

(ii) Sensorless Commutation (2nd Embodiment (Δ))

The active phase coils in each commutation state during PWM T1, PWM T2and PWM T3 intervals in the 2nd embodiment (Δ) are summarized in Table15, Table 16, Table 17 respectively. The corresponding commutation pointfunction detection and the phase winding power transistor switchingsequence for each of the six commutation steps is shown in FIG. 27.

TABLE 15 PWM T1 interval phase coil switching states in the 2ndembodiment (Δ) Rotor Position Commutation Top Active Bottom ActiveSector θ State Phase Coil Phase Coil  0-60° 0 A+ B−, C−  60-120° 1 A+,B+ C− 120-180° 2 B+ A−, C− 180-240° 3 B+, C+ A− 240-300° 4 C+ A−, B−300-360° 5 A+, C+ B−

TABLE 16 PWM T2 interval phase coil switching states in the 2ndembodiment (Δ) Rotor Position Commutation Top Active Bottom ActiveSector θ State Phase Coil Phase Coil  0-60° 0 — C−, A−, B−  60-120° 1 —C−, B−, A− 120-180° 2 — A−, B−, C− 180-240° 3 — A−, C−, B− 240-300° 4 —B−, C−, A− 300-360° 5 — B−, A−, C−

TABLE 17 PWM T3 interval phase coil switching states in the 2ndembodiment (Δ) Rotor Position Commutation Top Active Bottom ActiveSector θ State Phase Coil Phase Coil  0-60° 0 — A−  60-120° 1 — B−, A−120-180° 2 — B− 180-240° 3 — C−, B− 240-300° 4 — C− 300-360° 5 — A−, C−

(f) Quasi Field Oriented Control

In the previously disclosed method of sensorless commutation, the statormagnetic field remains fixed while the rotor turns through an angle of60°. The relative angle between stator and rotor magnetic fields thuschanges from 120° to 60°. The maximum BLDC motor torque is produced whenthe angle between the stator and rotor magnetic fields is 90°.

This disclosure describes a quasi FOC method used to estimate continuousrotor position with which a constant 90° torque angle can be produced ina BLDCM to address this challenge and improve performance. It uses theinformation contained in the previously disclosed CPFs which in generalhave been found to exhibit sinusoidal waveform behaviour, as shown inthe BLDCM example in FIG. 23.

An inverse sine operation can be used to calculate the continuous rotorangle (φ) from the CPFs with the calculations given below, where CPFmaxis the peak amplitude of the CPF in each 60° rotor position sector:φ=sin⁻¹(CPF/CPFmax)/3(0°≤θ<30°)  (101)φ=60−sin⁻¹(CPF/CPFmax)/3(30°≤θ≤60°)  (102)

The estimated continuous rotor angle (φ) is then used to modulate thethird phase coil in each 60° commutation state. This disclosed QFOCcalculation step is shown in the operation flowchart in FIG. 25.

It should be noted that in practical applications, CPFs which do notexhibit sinusoidal waveform behaviour can also utilise other possiblecalculation methods or functions, for example, such as higher-orderpolynomial functions or piecewise linear functions, in order to deducecontinuous rotor angle (φ) from the measured CPF values, as required bythe disclosed QFOC method of operation.

(i) QFOC (1st Embodiment)

To implement the QFOC operation in the 1st embodiment of this invention,the active phase coil switching states during PWM T1 interval operationare modified as shown in Table 18. The QFOC modulated phase coil isswitched in a complimentary manner between the supply voltage (Vs) andground rail (0V), with the duty cycle proportional to the estimatedrotor position angle (φ). The corresponding commutation point functiondetection and the phase winding power transistor switching sequenceemploying QFOC for each of the six commutation steps is shown in FIG.26.

TABLE 18 PWM T1 interval quasi FOC operation phase coil switching statesin the 1st embodiment Rotor Top Bottom QFOC φ Position CommutationActive Active Modulated Sector θ State Phase Coil Phase Coil Phase Coil 0 → 60° 0 A+ C− B+− (0 → 100%)  60 → 120° 1 B+ C− A+− (100 → 0%) 120 →180° 2 B+ A− C+− (0 → 100%) 180 → 240° 3 C+ A− B+− (100 → 0%) 240 → 300°4 C+ B− A+− (0 → 100%) 300 → 360° 5 A+ B− C+− (100 → 0%)

(ii) QFOC (2nd Embodiment (Δ))

To implement the QFOC operation in the 2nd embodiment, the active phasecoil switching states during PWM T1 interval operation are modified asshown in Table 19. In this embodiment, the QFOC modulation uses eitherthe bottom or top side power transistor to switch the phase coil, with aduty cycle proportional to the estimated rotor position angle (φ). Thecorresponding commutation point function detection and the phase windingpower transistor switching sequence employing QFOC for each of the sixcommutation steps is shown in FIG. 27.

TABLE 19 PWM T1 interval quasi FOC operation phase coil switching statesin the 2nd embodiment (Δ) Rotor Top Bottom QFOC φ Position CommutationActive Active Modulated Sector θ State Phase Coil Phase Coil Phase Coil 0 → 30° 0 A+ B− C− (0 → 100%) 30 → 60° 0 A+ C− B− (100 → 0%) 60 → 90° 1A+ C− B+ (0 → 100%)  90 → 120° 1 B+ C− A+ (100 → 0%) 120 → 150° 2 B+ C−A− (0 → 100%) 150 → 180° 2 B+ A− C− (100 → 0%) 180 → 210° 3 B+ A− C+ (0→ 100%) 210 → 240° 3 C+ A− B+ (100 → 0%) 240 → 270° 4 C+ A− B− (0 →100%) 270 → 300° 4 C+ B− A− (100 → 0%) 300 → 330° 5 C+ B− A+ (0 → 100%)330 → 360° 5 A+ B− C+ (100 → 0%)

Rotor Magnetic Field Strength Measurement

The developed commutation point functions (CPF) disclosed in the zero tolow speed sensorless BLDCM operation present an opportunity to ascertainthe relative rotor magnetic field strength measurement and addresses thechallenge of BLDCM rotor performance monitoring in real time and overits entire life time of operation. During the development, it was foundthat the peaks (CPFmax) of the calculated CPFs are directly proportionalto the rotor magnetic field strength in a BLDCM. Thus the greater themaximum CPF value, the greater is the resultant rotor magnetic fieldstrength, as shown in FIG. 28 for CPFs calculated in practical BLDCmotors. This measurement is possible because the disclosed CPFsrepresent the phase winding inductance variations that depend on theBLDCM rotor inherent and magnetic saturation saliency, which is alsodirectly proportional to the magnetic field strength of its rotor.

To obtain a useful indicator of the relative rotor magnetic fieldstrength for use in BLDCM applications, the disclosed method involvesthe calculation of maximum CPF value (CPFmax) which is independent ofthe power supply voltage (Vs), as shown below:CPFmaxR=CPFmax/Vs  (103)

The resultant magnetic field strength saliency ratio (CPFmaxR) curvesare illustrated in FIG. 29. This calculation step during the zero to lowspeed sensorless BLDCM operation is shown in the flowchart in FIG. 25.

Sensorless Motor Temperature Measurement

A method of motor winding temperature measurement using phase currentand voltage measurements to calculate copper phase winding resistance,which is proportional to its temperature, is disclosed in U.S. Pat. No.4,083,001. High accuracy phase current measurement requirement however,increases controller's electronic circuit complexity, size and cost.

As an extension to the previously disclosed rotor magnetic fieldstrength measurement, it was found that the same CPFmaxR measurement canalso be used to indicate the relative motor temperature during real timeoperation. Those skilled in this art can appreciate that this phenomenonoccurs because the magnetic field strength of a rotor is directlyproportional its temperature. FIG. 29 illustrates the typical rotormagnetic saliency ratio curves for BLDC motors exposed to differentoperating temperatures. As tested, the calculated CPFmaxR valuesdecrease with increasing temperature. FIG. 30 shows an example of BLDCMCPFmaxR variation with increasing motor temperature measured inpractice.

This relationship between the motor temperature and the rotor magneticfield strength saliency ratio (CPFmaxR) has been found to be linear forcommon BLDC motors tested. In practice, BLDC motors consisting ofdifferent electrical and mechanical construction and rotor magneticfield strength, also exhibit different CPFmaxR profiles. In thedisclosed sensorless motor temperature measurement method, precise motortemperature measurements are obtained by tuning the individual BLDCmotor temperature and CPFmaxR profiles. This is achieved by firstmeasuring two pairs of motor temperature and magnetic field strengthsaliency ratio (CPFmaxR) measurements at cold (CPFmaxR_T1, T1) and hot(CPFmaxR_T2, T2) motor temperatures, as illustrated in FIG. 31. Themotor temperature can then be calculated directly from the CPFmaxRmeasurements obtained during the previously disclosed zero to low speedsensorless BLDCM operation via the following straight line equation:T=T2+(T1−T2)·(CPFmaxR−CPFmaxR_T2)/(CPFmaxR_T1−CPFmaxR_T2)  (104)

The disclosed embodiment of sensorless motor temperature measurementmethod, using a straight line approximation, is illustrated in FIG. 31.For BLDC motors with measured CPFmaxR vs motor temperature profileswhich do not exhibit a straight line proportional relationship, a highorder polynomial equation can be used to obtain the required CPFmaxR tomotor temperature (T) relationship mapping.

The disclosed method can thus be used to monitor a BLDC motortemperature during operation without any additional temperature sensinghardware and electronic circuitry, saving system cost and increasingoperational reliability. This calculation step during the zero to lowspeed sensorless BLDCM operation is shown in the flowchart in FIG. 25.

Low to High Speed Sensorless BLDCM Operation

The RIMS saliency based initial rotor position detection and the zero tolow speed sensorless BLDCM commutation technique disclosed in previoussections provide faultless motor starts and operation at and near zerospeeds. This section discloses a second sensorless BLDCM controllermethod developed to operate BLDCMs at low and high motor speeds. Thispart of the hybrid controller approach is illustrated in FIG. 1.

The developed sensorless brushless commutation point detection (CPD)method employs conventional BEMF open phase voltage measurements tooperate BLDCMs at very high speeds. To extend sensorless BLDCM operationinto the low speed region and close to zero speeds, the disclosed methodalso utilizes inductance variations voltage measurements due to RIMSsaliency to detect accurate rotor position and commutation points.

Several prior art solutions which utilize inductance variations todetect sensorless commutation points in BLDCM applications are known.CH698071 presents a technique of measuring the inductance variationvoltage at the open-phase terminals during PWM on-time and off-timemotor driving switching intervals. From these +30° advanced timing motorcommutation points are obtained. However, these have the significantdisadvantage of reduced output motor torque and efficiency. U.S. Pat.Nos. 7,768,226 and 9,391,553 use inductance variation voltagemeasurements to determine the commutation points, however these methodsrequire additional hardware circuitry as well as a fourth motor neutralpoint connection which limits the range of possible applications only towye configuration BLDC motors. US20140062364 describes another similarmethod requiring motor's neutral point information to obtain sensorlesscommutation points, however in this method an external circuit is neededto simulate a virtual motor neutral point. U.S. Pat. Nos. 8,552,671 and8,593,098 rely on changes in phase current measurements due toinductance variations to determine commutation points, however thesemethods require expensive and accurate current sensing measurementcircuitry. U.S. Pat. No. 8,773,060 describes a technique of commutationpoint detection utilizing voltage measurements due to inductancevariations and addressing the challenge of operation at higher BLDCmotor temperatures. However, this method requires motor temperaturemeasurement using external temperature sensors built into the motor andassociated electronic circuitry, increasing the system costs. It alsorequires more complicated learning algorithms to adjust the commutationpoint detection voltage thresholds for BLDC motors operating atdifferent temperatures.

In contrast to prior art methods, the disclosed low to high speedsensorless BLDCM method uses the peaks of commutation point functions(CPFmax), measured during the previously disclosed zero to low speedsensorless BLDCM operation, to set the optimum commutation pointdetection voltage threshold levels. The resultant commutation points areoptimum at all motor temperatures and exhibit quasi 0° commutationtiming for maximum motor driving torque. To address the challenge ofincreased controller efficiency during PWM off-time switching, asoftware controlled PWM synchronous rectifier is also integrated intothe PWM switching sequence to control optimum synchronous rectifieron-time duration. Standard PWM switching technique is used to controlmotor driving phase currents. The developed PWM switching sequence whenB+/C− coil pair is energized is illustrated in FIG. 32.

The key innovations of the disclosed sensorless BLDC motor operationinclude: 1) A Robust and simple commutation point detection (CPD) methodimplemented during PWM on-time (PWM TON) switching interval, employinginductance voltage variations due to RIMS saliency and maximum values ofthe commutation point functions (CPFmax) measured during zero to lowspeed sensorless BLDCM operation; 2) Optimum commutation point detectionvoltage threshold setting for each BLDCM application, with quasi 0°commutation timing and automatic CPD voltage threshold compensation formotor temperature variations; 3) Sensorless BLDCM operation near zerospeeds, low and high motor speeds; 4) Software controlled PWMsynchronous rectification (PWM TSR), optimally controlled during PWMoff-time (PWM TOFF) switching interval, to increase controllerefficiency; 5) Reduced controller hardware complexity and cost.

The operation flowchart of the disclosed low to high speed sensorlessBLDCM controller operation is illustrated in FIG. 34.

(a) Quasi 0° Timing Commutation Point Detection at Low Speeds

Conventional sensorless brushless operation utilizes BEMF voltagesduring PWM on-time to detect commutation points when the measured openphase voltage crosses the half way point of the supply voltage rail(Vs/2). Compared to the ideal 0° timing commutation intervals, thispoint occurs at +30° advanced timing, resulting in reduced motor torqueand efficiency. To overcome this challenge, the sensorless BLDCMcommutation point detection method disclosed employs offset voltagethresholds with which quasi 0° commutation timing points are attained.

(i) PWM On-time Open Phase and Supply Voltage Measurement

The first two steps of the disclosed method involve energizing a pair ofphase coils and measuring the open phase and supply phase voltage (Vs),as shown in the PWM switching example in FIG. 32, with B+/C− as theactive coil pair and Va the open phase coil measurement. This voltagemeasurement technique is similar to the Von and Vs measurement disclosedin previous sections of this controller discussion (see FIG. 8). Thesetwo initial steps of operation are illustrated in the flowchart in FIG.34.

(ii) PWM On-time Commutation Point Detection

RIMS saliency properties are utilized next to detect accurate sensorlesscommutation points during the PWM on-time switching interval at lowmotor speeds. An example of this is shown in FIG. 33 where open phase Ameasurements are used. To ensure open phase voltage variations occurringdue to changing phase coil inductances are measurable during this PWMinterval, it was found the following conditions have to be satisfied:

1. Minimum PWM on-time duration is limited to ˜15 us. This ensures thata phase current pulse with sufficient amplitude is injected into theenergized coils to evoke RIMS saliency effects in the open phase voltagemeasurements required for commutation point detection

2. At 100% PWM duty cycle of operation, RIMS saliency effects are notmeasurable. Thus in practice, during operation at near zero and lowspeed the maximum PWM on-time duty cycle is restricted to ˜95%

To obtain reliable sensorless BLDCM operation commutation points, avoltage threshold offset corresponding to a factor of the maximummagnitude of the trough or peak voltage (CPFmax/2) is added to Vs/2, asillustrated in FIG. 33. CPFmax is the maximum value of the commutationpoint functions measured during zero to low speed sensorless BLDCMoperation, disclosed previously. CPFmax is approximately equal to twicethe magnitudes of the open phase output voltage peaks and troughsmeasured during low to high speed sensorless operation. Near zero andlow speed of operation, the offset H→L and L→H CPD voltage thresholds(marked with circles in FIG. 33) produce reliable commutation points,with timing very close to the ideal 0° timing commutation points (at 0°,60°, 120°, 180°, 240°, 300° electrical rotor positions). This step isillustrated in the operational flowchart in FIG. 34.

(iii) PWM On-time H→L and L→H CPD

The following two commutation point detection thresholds are calculatedduring PWM on-time interval for each open phase voltage measurement inthe commutation sequence. FIG. 33 show the resultant quasi 0°commutation timing points, which are optimal at any motor temperature:H→L Open Phase Voltage CPD Threshold: Vs/2−N·CPFmaxL→H Open Phase Voltage CPD Threshold: Vs/2+N·CPFmax

Where: CPFmax is the maximum value of the commutation point functionmeasured during zero to low speed sensorless BLDCM operation. It isdependent on BLDC motor temperature, as disclosed previously above. Thescaling factor, N is used to adjust the voltage threshold offset leveland the resultant quasi 0° commutation timing point. Values in the rangeof 0.25-0.5 were tested to work well in practice. Vs is the supplyvoltage measured during PWM on-time

(iv) PWM On-time Commutation Point Detection Calculations

In one complete BLDCM electrical rotor cycle, the disclosed commutationpoint detection calculations during PWM on-time interval for the sixcommutation states corresponding are given by:CP0=Vs·(½+N·CPFmaxR)−Vb(0°≤θ<60°)  (105)CP1=Va−Vs·(½−N·CPFmaxR)(60°≤θ<120°)  (106)CP2=Vs·(½+N·CPFmaxR)−Vc(120°≤θ<180°)  (107)CP3=Vb−Vs·(½−N·CPFmaxR)(180°≤θ<240°)  (108)CP4=Vs·(½+N·CPFmaxR)−Va(240°≤θ<300°)  (109)CP5=Vc−Vs·(½−N·CPFmaxR)(300°≤θ<360°)  (110)

Where: CPFmaxR is the supply voltage independent ratio value(CPFmax/Vs), disclosed previously in equation (103); Va, Vb, Vc are theopen phase voltages measured during PWM on-time switching intervals (PWMTON) in the corresponding commutation state interval. Vs is the supplyvoltage measured during PWM on-time. The commutation point is detectedwhen the calculated CP≤0. This step is illustrated in the operationalflowchart in FIG. 34.

(b) Synchronous Rectification During PWM Off-time

Some prior art solutions employing synchronous rectification techniquesin brushed motor control applications are disclosed in U.S. Pat. Nos.6,384,555 and 6,956,359. However, these solutions require additionalhardware circuitry to perform this function and thus have highercontroller cost. Furthermore, it is likely that no prior art solutionhas specifically addressed the challenge of synchronous rectification insensorless brushless BLDC motor applications.

The disclosed low to high speed sensorless operation integrates asoftware controlled synchronous rectification technique during PWMoff-time to reduce controller power loses. A practical example of therealized synchronous rectification operation is shown in FIG. 35, wherethe synchronous rectifier switch is activated for the optimal duration(T_(SR)). This operational step is illustrated in the flowchart in FIG.34 and is disclosed in greater detail in proceeding section. Theembodying software controlled synchronous rectifier operation flowchartis presented in FIG. 46.

(c) Commutation Point Detection at High Speeds

At higher speeds of operation, the disclosed commutation point detectionduring PWM on-time interval automatically reverts to operationequivalent to the conventional sensorless brushless commutation pointdetection utilizing BEMF voltage measurements. The commutation timingincreases from the quasi 0° to 30°, which can be retarded back to 0°using time delay techniques that are well know to those skilled in thisart.

(d) Sensorless BLDCM Commutation and Synchronous Rectifier Phase CoilsSwitching States

The active phase coils in each commutation state during PWM T_(ON) andPWM T_(SR) switching intervals are equivalent to the previouslydisclosed states in Table 12 and Table 13 respectively. The CPs andcorresponding PWM on-time and synchronous rectifier phase coil switchingstates for one complete electrical revolution in a BLDC motor areillustrated in FIG. 36.

(e) Low to High Speed Sensorless BLDCM Operation Extensions

The disclosed low to high speed sensorless BLDCM operation has beenpresented for the case of high-side PWM switching topology, commonlyused with bootstrapped transistor gate drivers. However, the disclosedtechnique of commutation point detection and software controlledsynchronous rectification can be applied to any other PWM switchingtopology, such as for example, low-side PWM switching and alternatelow-high side PWM switching, in order to make optimum use of theimplemented controller hardware circuitry.

Software Controlled PWM Synchronous Rectification

Synchronous rectification (SR) is a technique used to improve controlleroutput efficiency during PWM switching operation with inductive loads.Generally, this operation is implemented with external hardwarecircuitry which increases overall system cost, as for example disclosedin U.S. Pat. Nos. 6,384,555, 6,396,250, 6,861,826 and 6,956,359.

This section discloses a synchronous rectification method implementedentirely with a software feedback control algorithm, which does notrequire any additional hardware. It is integrated into the previouslydisclosed low to high speed sensorless BDLCM operation and theregenerative BLDC motor braking disclosed in proceeding section.

(a) Synchronous Rectification Background

In inductive load PWM switching applications, such as BLDC motors, thephase current which rises exponentially during PWM on-time intervalcontinues to flow in the PWM off-time interval. Normally this currentflow is maintained via a freewheeling diode, either integrated into thesemiconductor switch, such as a MOSFET or IGBT, or by a discrete diodedevice. Improvement in efficiency can be made when the freewheelingdiode is replaced with a lower resistance semiconductor device to carrythe phase current during PWM off-time. The timing of this operation isimportant and must be synchronized with the PWM off-time, hence thisprocess is called “synchronous rectification”. The following sectionoutlines the difference between these two methods commonly applied inthe prior art.

(i) Freewheeling Diode Rectifier

FIG. 37 illustrates the phase voltage and current during PWM switchingemploying a freewheeling diode during PWM off-time interval. Thecorresponding hardware circuit configuration when PWM on-time intervalB+/C− phase coils are activated is shown in FIG. 38. During thisinterval B_H and C_L switches are turned-on, resulting in current(I_(ON)) flowing through the active phases. When PWM off-time intervalis commenced, as shown in FIG. 39 and FIG. 37, B_H switch is turned-offand the internal body diode of B_L switch begins to conduct theexponentially decaying phase current (I_(OFF)). This switching actionoccurs automatically, hence the term “freewheeling” diode. During thisfreewheeling period, the conducting diode experiences a power lossproportional to its forward voltage drop and the magnitude of thecurrent:P _(d_FW) =V _(d) ·I _(OFF)[W]  (111)

This power loss, illustrated in FIG. 37, can be quite extensive whenswitching high phase currents, resulting in reduced output current(motor torque) and excessive heating of the freewheeling diode and hencethe semiconductor switching device, contributing to reduced outputefficiency.

(ii) Synchronous Rectifier

The phase voltage and current waveforms during PWM off-time synchronousrectifier operation are illustrated in FIG. 40. During this interval theB_H switch is turned-off and the synchronous rectifier switch B_L isturned-on, conducting the exponentially decaying phase current (I_(OFF))as illustrated in FIG. 41. The timing of this complementary switchingaction is critical, since B_L switch must be turned-off again whenI_(OFF)=0. Generally, specialized external hardware circuitry isnecessary to perform this task, increasing the overall system cost. Thesynchronous rectifier switch B_L also experiences a power loss, which isproportional to its on-resistance and the square of the phase current:P _(d_SR) =R _(ds_on) ·I _(OFF) ²[W]  (112)

With modern semiconductor switches, such as MOSFETs, exhibiting very lowsolid state on-resistance values (<1 mΩ), the power loss during thesynchronous rectifier operation, illustrated in FIG. 40, issignificantly less than during the freewheeling diode operation shown inFIG. 37. In practice, synchronous rectification increases thecontroller's output efficiency during PWM off-time interval by reducingthe heating in the semiconductor switches. The motor phase currents arealso higher during PWM off-time switching interval, thus increasing theaverage motor torque during operation.

(b) Software Synchronous Rectifier Feedback Controller

This section discloses the synchronous rectifier feedback controlalgorithm implemented in software, which was developed to eliminateadditional hardware circuitry found in the prior art. The objective ofthe feedback controller is to maintain a zero phase current at the endof the SR period during the PWM off-time interval. This produces theoptimal synchronous rectifier duration synonymous with the prior artexternal hardware solutions. Depending on the length of SR duration(T_(SR)) with respect to the PWM off-time interval duration (T_(OFF))two distinct SR feedback control measurement techniques are employed.The disclosed synchronous operation flowchart is presented in FIG. 46.On the very first PWM cycle, the synchronous rectifier duration T_(SR)is initialized to a known value, generally to 0.

(c) SR Feedback Voltage (VFB) Measurement

The disclosed software controlled synchronous rectifier requires themeasurement of the feedback voltage (V_(FB)) at the end of thesynchronous rectification duration (T_(SR)). This task is shown inoperation flowchart in FIG. 46.

(d) SR Feedback Controller with T_(SR)<T_(OFF)

In operation at low inductive loads, for example when a BLDCM hasreached higher speeds, the phase currents may have sufficient time todecay to zero before reaching the end of PWM off-time interval(T_(OFF)). During this discontinuous phase current mode of PWM operationthe SR duration (T_(SR)) is less than the entire PWM off-time duration(T_(OFF)). Illustrated in FIG. 42 and FIG. 43, two distinct SR feedbackmeasurements are possible at the end of the SR interval, depending onthe value of feedback phase current, I_(FB). These steps are shown inthe SR operation flowchart in FIG. 46.

(i) SR I_(FB)>0 (V_(FB)>0)

The phase voltage and current waveforms and power transistor switchingstates during SR feedback control operation when I_(FB)>0 are shown inFIG. 42, in which B and C phase windings are active. In this case, theSR duration (T_(SR)) is shorter than the optimum duration, resulting in“under” rectification. Consequently, when the synchronous rectifierswitch is turned-off (C_L=0, B_L=1) the residual positive feedbackcurrent generates a positive feedback voltage (V_(FB)), which ismeasured at phase C terminal (VC) and is used by the SR feedbackcontroller to increase the SR duration (T_(SR)) in the next PWM cycle.The width of the feedback duration (T_(FB)) depends on the time requiredto decay I_(FB) to zero and in practice, it is regulated by the PWMsynchronous rectification feedback controller.

(ii) SR I_(FB)<0 (V_(FB)<0)

The case when the SR duration (T_(SR)) is too long compared to theoptimal duration, resulting in “over” rectification, is illustrated inFIG. 43 with B and C phase windings active. In this case the SR current(I_(SR)) reaches a negative value during the SR interval. When thesynchronous rectifier switch is turned-off (C_L=0, B_L=1), this negativecurrent continues to decay to zero during the feedback measurementinterval (T_(FB)) generating in a negative feedback voltage (V_(FB))measured at phase C terminal (V_(C)). This negative V_(FB) voltage valueis used by the SR feedback controller to decrease the SR duration(T_(SR)) in the next PWM cycle.

(iii) SR Feedback Control Law with T_(SR)<T_(OFF)

The SR feedback control law during SR operation with T_(SR)<T_(OFF) isgiven by:

-   -   If V_(FB)>0 then increase T_(SR) duration    -   If V_(FB)≤0 then decrease T_(SR) duration

In practice the T_(SR) duration can be regulated using simple incrementand decrement algorithms, with the speed of response weighed accordingto application requirements. One example implemented is given by:T _(SR)[n+1]=T _(SR)[n]±ΔT _(SR) ·W  (113)

Where: ΔT_(SR) is the increment/decrement step; W is theincrement/decrement weight used to adjust the feedback controllerresponse speed. More advanced control techniques, such as PID can alsobe implemented to regulate the SR feedback control loop.

(e) SR Feedback Controller with T_(SR)=T_(OFF)

During operation at high inductive loads, typically when a BLDCM isstarting and the speed is low, the phase currents do not have sufficienttime to decay to zero before reaching the end of the PWM off-timeinterval (T_(OFF)). This results in a continuous phase current mode ofPWM operation. In this case, the SR duration (T_(SR)) reaches itsmaximum possible value, equal to the entire PWM off-time duration(T_(OFF)). Similar to operation when T_(SR)<T_(OFF) disclosed inprevious section, two distinct SR feedback measurements illustrated inFIG. 44 and FIG. 45 are also possible at the end of the SR interval(T_(SR)), depending on the value of feedback phase current (I_(FB)).These steps are shown in the SR operation flowchart in FIG. 46.

(i) SR I_(FB)>0 (V_(FB)<0)

The phase voltage and current waveforms and power transistor switchingstates during SR feedback control operation when I_(FB)>0, are shown inFIG. 44 with B and C phase windings active. In this case, the SRduration (T_(SR)), which is limited to T_(OFF), is shorter than theoptimum duration, resulting in under-rectification. Consequently, thepositive feedback current (I_(FB)) generates a negative feedback voltage(V_(FB)) measured at phase B terminal (V_(B)) when synchronous rectifierswitch is turned-off (B_L=0, C_L=1). In this mode of SR operation thefeedback current (I_(FB)) does not have sufficient time to decay tozero, and thus a continuous current is maintained in subsequent PWMoperation cycles. This negative V_(FB) voltage value is used by the SRfeedback controller to increase the SR duration (T_(SR)) in the next PWMcycle.

(ii) SR I_(FB)<0 (V_(FB)>0)

The case when the SR period is too long, resulting inover-rectification, is illustrated in FIG. 45 with B and C phasewindings active. In this case, the SR current (I_(SR)) reaches anegative value during the SR interval. This negative current continuesto decay during the feedback measurement interval (T_(FB)) producing apositive feedback voltage (V_(FB)) measured at phase B terminal (V_(B))when synchronous rectifier switch is turned-off (B_L=0, C_L=1). Thispositive V_(FB) voltage value is used by the SR feedback controller todecrease the SR duration (T_(SR)) in the next PWM cycle.

(iii) SR Feedback Control Law with T_(SR)=T_(OFF)

The SR feedback control law during SR operation with T_(SR)=T_(OFF) isgiven by:

-   -   If V_(FB)≤0 then increase T_(SR) duration    -   If V_(FB)>0 then decrease T_(SR) duration

T_(SR) duration is regulated using the same methods previously outlinedfor the SR feedback control law with T_(SR)<T_(OFF).

(f) Software Synchronous Rectifier Extensions

The disclosed software controlled synchronous rectification has beenpresented for the case of high-side PWM switching topology, commonlyused with bootstrapped transistor gate drivers. However, the disclosedtechnique can be applied to any other PWM switching topology, such asfor example, low-side PWM switching and alternate low-high side PWMswitching.

It is also evident that the disclosed software controlled synchronousrectification method can be applied to any inductive PWM switchingapplication, such as for example, DC/DC power supplies, during normalmotor driving and motor braking operation of brushed motors, sensorlessbrushless motors and sensored brushless motors.

Regenerative Motor Braking with Synchronous Rectification

This section discloses the regenerative motor braking method forsensorless BLDC motor applications, which is integrated into thiscontroller invention as shown in FIG. 1. Compared to the prior artregenerative motor braking solutions employing freewheeling diodes toconduct motor braking currents during PWM off-time switching interval,such as described in U.S. Pat. No. 9,246,416 for a sensored BLDC motorsystem application, the method disclosed integrates the softwarecontrolled synchronous rectification technique disclosed previously.

The disclosed method address the following key challenge areas ofregenerative motor braking applications compared to the prior art: 1)Increased controller efficiency, resulting in reduced power and heatinglosses during regenerative motor braking; 2) Increased level of energyreturned back to the power source, resulting in increased time ofoperation in applications such as battery powered applications; 3)Reduced controller hardware complexity and cost, requiring no additionalcircuitry to increase regenerative motor braking performance.

(a) Commutation Point Detection

Conventional sensorless brushless commutation point detection methods,known to those skilled in this art, utilizing BEMF voltage measurementsare employed during the regenerative BLDC motor braking. These can beapplied during PWM on-time and off-time intervals shown in FIG. 47.

(i) PWM On-Time CPD

As illustrated in the example of FIG. 47, during the PWM on-timeinterval (T_(ON)) the active phase coils (B−/C−) are connected to the 0Vsupply rail, short-circuiting the phase windings. The BEMF voltagesgenerated by a rotating permanent magnet induce a phase current (I)which rises exponentially. The commutation point is detected via theopen phase coil (A) voltage output (V_(a)) when the 0V rail is crossed.The detected commutation points occur at +30° advanced timing angle andare measured using the following equations for each of the sixcommutation state intervals:CP0_Ton=−Vb(330°≤θ<30°)  (114)CP1_Ton=Va(30°≤θ<90°)  (115)CP2_Ton=−Vc(90°≤θ<150°)  (116)CP3_Ton=Vb(150°≤θ<210°)  (117)CP4_Ton=−Va(210°≤θ<270°)  (118)CP5_Ton=Vc(270°≤θ<330°)  (119)

The commutation point is detected when the calculated CP≤0. This step isillustrated in the regenerative motor braking operation flowchart inFIG. 49.

(ii) PWM Off-time CPD with Synchronous Rectifier

During this PWM off-time interval, the active phase coils (B+/C−) areconnected between the supply voltage rails, as illustrated in exampleFIG. 47, allowing the phase current to decay exponentially to zerothrough the optimal software controlled synchronous rectifier disclosedpreviously, thus increasing controller efficiency. In this example, thecommutation point is detected via the open phase coil (A) voltage output(Va) when this voltage crosses the half way point of the supply voltagerail (Vs/2). The detected commutation points occur at +30° advancedtiming angle and are measured using the following equations for each ofthe six commutation state intervals:CP0_Tsr=½·Vs−Vb(330°≤θ<30°)  (120)CP1_Tsr=Va−½·Vs(30°≤θ<90°)  (121)CP2_Tsr=½·Vs−Vc(90°≤θ<150°)  (122)CP3_Tsr=Vb−½·Vs(150°≤θ<210°)  (123)CP4_Tsr=½·Vs−Va(210°≤θ<270°)  (124)CP5_Tsr=Vc−½·Vs(270°≤θ<330°)  (125)

The commutation point is detected when the calculated CP≤0. This step isillustrated in the regenerative motor braking operation flowchart inFIG. 49.

(iii) PWM Off-time CPD with Phase Current Equal to Zero (I=0)

In this PWM off-time interval only one active phase coil (C−) isconnected to the 0V rail via the C_L switch after the phase current hasdecayed to zero, as illustrated in the example of FIG. 47. In thisinterval, the commutation point is detected via the BEMF generated openphase voltage outputs Va and Vb of the inactive phase coils (A and B).During this off-time interval, the +30° timing commutation points foreach of the six commutation states are obtained directly from themeasured BEMF voltages at the open phase outputs using the followingcalculations:CP0_Toff=½·Va−Vb(330°≤θ<30°)  (126)CP1_Toff=Va−½·Vb(30°≤θ<90°)  (127)CP2_Toff=½·Vb−Vc(90°≤θ<150°)  (128)CP3_Toff=Vb−½·Vc(150°≤θ<210°)  (129)CP4_Toff=½·Vc−Va(210°≤θ<270°)  (130)CP5_Toff=Vc−½·Va(270°≤θ<330°)  (131)

The commutation point is detected when the calculated CP≤0. This step isillustrated in the regenerative motor braking operation flowchart inFIG. 49.

(b) Synchronous Rectification during PWM Off-time

A practical example of the disclosed synchronous rectification operationduring regenerative motor braking is shown in FIG. 48. The optimalsoftware controlled synchronous rectifier switch is activated forduration T_(SR). This operational step is illustrated in the flowchartin FIG. 49 and was disclosed in greater detail previously.

(c) Sensorless BLDCM Brake Operation Commutation and SynchronousRectifier Phase Coils Switching States

The following section outlines the phase coil switching states duringPWM on-time and off-time intervals in the disclosed BEMF sensorless 60°step regenerative motor braking operation. The CP and corresponding PWMon-time and synchronous rectifier phase coil switching states for onecomplete electrical revolution in a BLDC motor are illustrated in FIG.50.

(i) PWM On-time Interval Active Phase Coils

Table 20 shows the active phase coils during PWM T1 on-time interval ofoperation.

TABLE 20 PWM on-time active phase coils during sensorless motor brakeoperation Rotor Position Commutation Top Active Bottom Active Sector θState Phase Coil Phase Coil 330-30°  0 — C−, A− 30-90° 1 — C−, B− 90-150° 2 — A−, B− 150-210° 3 — A−, C− 210-270° 4 — B−, C− 270-330° 5 —B−, A−

(d) PWM Off-time Synchronous Rectifier Interval Active Phase Coils

Table 21 shows the active phase coils during PWM off-time interval ofoperation, employing the synchronous rectifier technique to control thephase current.

TABLE 21 PWM off-time synchronous rectifier active phase coils duringsensorless motor brake operation Rotor Position Commutation SynchronousRectifier Bottom Active Sector θ State (Top Active) Phase Coil PhaseCoil 330-30°  0 A+ C− 30-90° 1 B+ C−  90-150° 2 B+ A− 150-210° 3 C+ A−210-270° 4 C+ B− 270-330° 5 A+ B−

(e) PWM Off-time (I=0) Active Phase Coils

Table 22 shows the active phase coils during PWM off-time interval ofoperation when the motor braking phase currents have decayed to zero(I=0).

TABLE 22 PWM off-time (I = 0) active phase coils during sensorless motorbrake operation Rotor Position Commutation Top Active Bottom ActiveSector θ State Phase Coil Phase Coil 330-30°  0 — C− 30-90° 1 — C− 90-150° 2 — A− 150-210° 3 — A− 210-270° 4 — B− 270-330° 5 — B−

(f) Regenerative Motor Braking Operation Extensions

The disclosed sensorless BLDC motor regenerative braking and softwarecontrolled synchronous rectification has been presented for the case ofhigh-side PWM switching topology, commonly used with bootstrappedtransistor gate drivers. However, the disclosed method can be applied toany other PWM switching topology, such as for example, low-side PWMswitching and alternate low-high side PWM switching. The disclosedmethod can also be applied to any sensored brushless motor brakingapplication employing rotor position detection sensors, such as HallEffect sensors used to perform electric brushless motor commutation.

Sensorless BLDCM Controller Integration

The complete integration of the disclosed sensorless BLDC motorcontroller embodiments is shown in FIG. 1.

(a) High Speed BLDC Motor Start

If a BLDC motor has high rotational speed at the start, which forexample is commonly encountered in mobility equipment such as electricvehicles, then the BEMF voltage waveform magnitudes and phases can beused to deduce the initial rotor position and then consequently engagethe low to high speed sensorless BLDCM controller operation, as shown inFIG. 1.

(b) Crossover Sensorless BLDCM Operation

A crossover to high or zero-to-low speed sensorless BLDCM operation canbe performed when a set motor speed level is reached. This method hasbeen found to work well in most practical BLDCM applications.Combinations with other methods, for example, such as when a set PWMduty cycle level is demanded can also be implemented.

(c) Sensorless BLDCM Controller Integration Extensions

In certain BLDCM application where robust start-up provided by the zeroto low speed SBLDCM operation is not required, it is also possible tostart and operate a BLDC motor directly with the disclosed low to highspeed SBLDCM controller operation, which is capable of operating motorsnear zero speed without rotation direction detection and with increasedstart-up motor torque.

Three-phase Optimized Power Control PCB Layout

This section discloses the three-phase power control PCB layout designwith an improved functional performance over the prior art PCB designs.It is evident that the PCB layouts used in three-phase power controlapplications generally consist of a rectangular power transistor layoutconfiguration. One such example is disclosed in U.S. Pat. No. 7,154,196.

In three-phase power control applications, such as professional R/Celectric vehicle racing these prior art rectangular power transistor PCBlayout designs as shown in FIG. 51 and FIG. 52 have the followingdisadvantages:

1) Increased output phase resistances and power losses due to relativelylarge PCB copper track distance between the external power wireconnections and power transistors furthest away from the wireconnections (for example PCB track distance between C4 power transistorand phase C power wire connection in FIG. 52).

2) Increased heating of the middle phase group (B1-B4 transistor groupin FIG. 52) of paralleled power transistors, due to heat concentrationin the middle of the PCB, leading to increased thermal stress andlikelihood of failure.

3) Unbalanced phase resistances and inductances due to different PCBtrack distances between the power transistors and the output power wireconnections (for example, A1-A4 transistor group and GND power wireconnection in FIG. 52), leading to increased voltage and current spikesin the phase group with the highest inductance and increased possibilityof damage to these power transistors during high speed switching andhigh current power applications.

In many three-phase power control applications, such as R/C electricvehicle motor controllers described in [30] and [31], it is necessary toprovide power wire connections outside of the controller casing to allowthe user to replace the wires when required. This requirement restrictsthe possible placement of the power wire pads locations on the PCB withrespect to the power transistors resulting in reduced PCB performancewith the rectangular PCB layouts.

(a) Radially Symmetrical Three-phase Power Controller PCB Layout

The disclosed three-phase power control PCB layout configurationimproves on the problems of the prior art designs with a novel radiallysymmetrical power PCB layout. Practical examples of three differentembodiments implemented in practice are shown in FIG. 53, FIG. 54 andFIG. 55. The radial symmetry allows the external power wire connectionsto be placed in the middle of each phase transistor group thussignificantly reducing the PCB copper track resistances in each phase.This step discloses a radially symmetrical power PCB configuration.

(i) Key Design Differences of the Radially Symmetrical Three-phase PowerController PCB Layout

As shown in example embodiments in FIG. 53, FIG. 54 and FIG. 55, the keydesign differences of the disclosed three-phase power control PCB layoutcompared to the prior art are:

1) Groups of paralleled (or single) power transistors (low-side andhigh-side switching) belonging to each phase are placed in radialsymmetry about the center of PCB on the top and, or bottom PCB layers.

2) Phase output power wire connections are placed in the middle of eachpower transistor group geometry, thus physically reducing the PCB coppertrack resistance in each phase.

(ii) Key Performance Advantages of the Radially Symmetrical Three-phasePower Controller PCB Layout

The placement of power transistors in radial symmetry with respect tothe center of the PCB makes it possible to address the followingchallenges in three-phase power control applications:

1) Reduced phase output resistances in a similar PCB footprint size.

2) Reduced PCB power losses and thermal losses and increased efficiency.

3) More even heat distribution amongst the power transistors in eachphase, reducing regions of hot spots.

4) More balanced phase resistances and inductances in all powertransistor phase groups, reducing the likelihood of power transistordamage during high speed switching and high current power applications.

5) Reduced PCB manufacturing costs due to the reduced PCB copper trackthickness and lesser number of layers required to achieve the sameoutput efficiency as prior art designs.

6) Improved power PCB performance with controller case designs requiringexternal power wire connections to the PCB.

(iii) Electrical Connections of Low-side and High-side Power Transistorsof the Radially Symmetrical Three-phase Power Controller PCB Layout

In the disclosed radially symmetrical three-phase power PCB layoutconfiguration, such as shown in the example embodiments in FIG. 53, FIG.54 and FIG. 55, it is possible to electrically connect the switchingpower transistor in the following configurations:

Groups consisting of only the low-side (A_L, B_L, C_L) or only thehigh-side (A_H, B_H, C_H) switching power transistors (paralleled orsingle) placed on the same PCB layer.

One such practical embodiment is shown in FIG. 56, where the top PCBlayer consists of only low-side switching power transistors placed inthe disclosed radially symmetrical PCB layout configuration. In thisexample embodiment, the corresponding bottom PCB layer would consist ofonly the high-side switching power transistors placed in the disclosedradially symmetrical PCB layout configuration.

Groups consisting of both the low-side (A_L, B_L, C_L) and high-side(A_H, B_H, C_H) switching power transistors (paralleled or single)placed on the same PCB layer.

One such practical embodiment is shown in FIG. 57, where the top PCBlayer consists of both the low-side and the high-side switching powertransistors placed in the disclosed radially symmetrical PCB layoutconfiguration.

In the embodiment shown in FIG. 57, it is possible to place all of thelow-side and high-side PCB on the one side of the PCB layer, or on boththe top and bottom PCB sides by paralleling the power transistors placedon the opposite sides of the top and bottom PCB layers. Copper vias canbe used to complete electrical connections between the power transistorsplaced on the top and bottom layers.

(b) Practical Embodiment of Radially Symmetrical Three-phase PowerController PCB Layout

One practical embodiment of the disclosed radially symmetricalthree-phase optimized PCB layout, implemented in R/C electric vehicleBLDCM control applications, having four paralleled power transistors ineach phase group and power wire connections placed outside thecontroller casing is shown in FIG. 58, FIG. 59, FIG. 60 and FIG. 61.These figures correspond to the top, bottom and two internal powersupply PCB layers respectively:

Top layer consisting of paralleled low-side switching power transistorsA1-A4 (A_L), B1-B4 (B_L) and C1-C4 (C_L); Bottom layer consisting ofparalleled high-side switching power transistors A5-A8 (A_H), B5-B8(B_H) and C5-C8 (C_H); Connector (CN1) provides electrical connectionsto adjoining PCB containing embedded microcontroller and low powersignal circuitry; Internal GND power copper plane layer; Internal Vspower copper plane layer.

The internal GND and Vs power copper plane layers provide a lowresistance connection between the groups of power transistors in eachphase (A, B, C) and the GND and Vs external power wire connection pads.In practice each power plane layer (GND, Vs) consists of two or moreinternal copper layers of the same design stacked on top of each otherwithin the PCB to reduce the power connection resistance as low aspossible. The connections between the top, bottom and internal layersare provided by the small diameter through-hole vias. Thus a completepower PCB design can include a total of six or more copper layers.

(c) Phase Circuit Resistance Analysis

The following section presents an analysis and comparison of the outputphase resistances for the prior art rectangular PCB layout and thedisclosed radially symmetrical PCB layout.

(i) Rectangular PCB Layout Phase Circuit Resistance Analysis

FIG. 62 shows a simplified prior art rectangular PCB layout phaseresistance model consisting of a network of power transistors (Rt) andequally spaced copper track resistance paths (R) joining a group of fourpower transistors (PQFN 5×6 mm package [29]) for the rectangular PCBembodiment in FIG. 52. The total phase resistance is given by:Rph_rec=1/(1/(2·R+1/(1/(2·R+1/(1/Rt+1/(2·R+Rt)))+1/Rt))+1/Rt)+2·R  (132)

(ii) Radially Symmetrical PCB Layout Phase Circuit Resistance Analysis

FIG. 63 shows a simplified radially symmetrical PCB layout phaseresistance model consisting of a network of power transistors (R_(t))and equally spaced copper track resistance paths (R) joining a group offour power transistors (PQFN 5×6 mm package [29]) for the radiallysymmetrical PCB embodiment in FIG. 58. The total phase resistance isgiven by:Rph_sym=½·(2·R+1/(1/Rt+1/(2·R+Rt)))  (133)

(iii) Total Phase Resistance Comparison

FIG. 64 shows the estimated total phase resistance of the prior artrectangular PCB layout of embodiment in FIG. 52 (Rph_rec) and of thedisclosed radially symmetrical PCB layout of embodiment in FIG. 58(Rph_sym). The calculated total phase resistances are normalized to theunit PCB track length resistance (R=1) and varied with the normalizedpower transistor resistance (Rt). As shown in FIG. 64, the total phaseresistance of the rectangular PCB layout is in the order of 2 (Rt=0) to1.5 (Rt=10) times higher than that of the radially symmetrical PCBdesign. Thus, the disclosed method offers a significant performanceadvantage in the same PCB size.

In practical three-phase power control power PCB layout embodiments suchas in FIG. 52 and FIG. 58, the unit PCB copper track resistance (R) canbe approximated with the following calculation:R=ρ·L/(W·T)  (134)

Where: ρ=1.69×10⁻⁸ Ω/m (copper resistivity at 20° C.); L=0.005 m (unitPCB copper length between adjacent power transistors, approximatelyequal to power transistor width [29]); W=0.005 m (PCB copper trackwidth); T=100×10⁻⁶ m=0.5×10⁻⁶ m² (PCB copper thickness 100 um (3 oz.)

Thus, the unit PCB copper track resistance (R) is approximately equalto:R=1.69×10⁻⁸Ω/m·0.005m/(0.005m·100×10−6m)=0.169mΩ  (135)

A modern power transistor switching device such as the InternationalRectifiers IRFH5300PbF [29] commonly used in BLDCM power controlapplications has a typical RDS on-resistance (Rt) equal to 1.4 mΩ. Thus,in this example the normalized power transistor resistance (Rt) is equalto:Rt=1.4mΩ/0.169mΩ≈8.3  (136)

With Rt=8.3, the rectangular PCB layout has approximately 5.4/3.3≈1.6times higher phase resistance than the radially symmetrical PCB layout,as shown in FIG. 64. This is about 60% higher.

(d) Radially Symmetrical PCB Layout Extensions

The disclosed radially symmetrical PCB layout can be employed in anythree-phase power control applications such as, but not limited to: 1)Three-phase BLDC motor controllers (sensored, sensorless); 2)Three-phase BLDC motors with controllers built inside the motor, such asdescribed in [32] (for example using circular PCB layout embodimentsdisclosed in FIG. 53, FIG. 54 and FIG. 55; 3) Three-phase powerinverters, power supplies (AC, DC).

The disclosed radially symmetrical PCB layout can be realized with anynumber of external and internal PCB conductive layers, for example, witha single sided PCB, a double sided PCB and a multiple layer PCB.

Furthermore, the disclosed radially symmetrical PCB layout can berealized with any number of paralleled power transistor devices in eachphase and with any of the available power transistor device packages andfootprints such as, but not limited to: PQFN, QFN, DPAK, D2PAK, PPAK,SO8, SOP8, SOT143, SOT23, SOT223, SOT523, SOT666, SOT89, TSOP6, TSSOP8,DirectFET, FlipFET, MicroFET, Micro8, PolarPAK, PowerPAK. Power 33,Power 56.

The disclosed radially symmetrical method of power transistor and powerwire placement on a PCB can also be employed in applications other thanthree-phase power control applications, for example, such as two-phase,four-phase or five-phase systems. In this case the radial angle betweeneach phase is adjusted according to the number of phases, for example,180° for two-phase, 90° for four-phase and 72° for five-phase system.

Interpretation

Reference throughout this specification to “one embodiment”, “someembodiments” or “an embodiment” means that a particular feature,structure or characteristic described in connection with the embodimentis included in at least one embodiment of the present invention. Thus,appearances of the phrases “in one embodiment”, “in some embodiments” or“in an embodiment” in various places throughout this specification arenot necessarily all referring to the same embodiment, but may.Furthermore, the particular features, structures or characteristics maybe combined in any suitable manner, as would be apparent to one ofordinary skill in the art from this disclosure, in one or moreembodiments.

As used herein, unless otherwise specified the use of the ordinaladjectives “first”, “second”, “third”, etc., to describe a commonobject, merely indicate that different instances of like objects arebeing referred to, and are not intended to imply that the objects sodescribed must be in a given sequence, either temporally, spatially, inranking, or in any other manner.

In the claims below and the description herein, any one of the termscomprising, comprised of or which comprises is an open term that meansincluding at least the elements/features that follow, but not excludingothers. Thus, the term comprising, when used in the claims, should notbe interpreted as being limitative to the means or elements or stepslisted thereafter. For example, the scope of the expression a devicecomprising A and B should not be limited to devices consisting only ofelements A and B. Any one of the terms including or which includes orthat includes as used herein is also an open term that also meansincluding at least the elements/features that follow the term, but notexcluding others. Thus, including is synonymous with and meanscomprising.

As used herein, the term “exemplary” is used in the sense of providingexamples, as opposed to indicating quality. That is, an “exemplaryembodiment” is an embodiment provided as an example, as opposed tonecessarily being an embodiment of exemplary quality.

It should be appreciated that in the above description of exemplaryembodiments of the invention, various features of the invention aresometimes grouped together in a single embodiment, figure, ordescription thereof for the purpose of streamlining the disclosure andaiding in the understanding of one or more of the various inventiveaspects. This method of disclosure, however, is not to be interpreted asreflecting an intention that the claimed invention requires morefeatures than are expressly recited in each claim. Rather, as thefollowing claims reflect, inventive aspects lie in less than allfeatures of a single foregoing disclosed embodiment. Thus, the claimsfollowing the Detailed Description are hereby expressly incorporatedinto this Detailed Description, with each claim standing on its own as aseparate embodiment of this invention.

Furthermore, while some embodiments described herein include some butnot other features included in other embodiments, combinations offeatures of different embodiments are meant to be within the scope ofthe invention, and form different embodiments, as would be understood bythose skilled in the art. For example, in the following claims, any ofthe claimed embodiments can be used in any combination.

Furthermore, some of the embodiments are described herein as a method orcombination of elements of a method that can be implemented by aprocessor of a computer system or by other means of carrying out thefunction. Thus, a processor with the necessary instructions for carryingout such a method or element of a method forms a means for carrying outthe method or element of a method. Furthermore, an element describedherein of an apparatus embodiment is an example of a means for carryingout the function performed by the element for the purpose of carryingout the invention.

In the description provided herein, numerous specific details are setforth. However, it is understood that embodiments of the invention maybe practiced without these specific details. In other instances,well-known methods, structures and techniques have not been shown indetail in order not to obscure an understanding of this description.

Similarly, it is to be noticed that the term coupled, when used in theclaims, should not be interpreted as being limited to direct connectionsonly. The terms “coupled” and “connected,” along with their derivatives,may be used. It should be understood that these terms are not intendedas synonyms for each other. Thus, the scope of the expression a device Acoupled to a device B should not be limited to devices or systemswherein an output of device A is directly connected to an input ofdevice B. It means that there exists a path between an output of A andan input of B which may be a path including other devices or means.“Coupled” may mean that two or more elements are either in directphysical or electrical contact, or that two or more elements are not indirect contact with each other but yet still co-operate or interact witheach other.

Thus, while there has been described what are believed to be thepreferred embodiments of the invention, those skilled in the art willrecognize that other and further modifications may be made theretowithout departing from the spirit of the invention, and it is intendedto claim all such changes and modifications as falling within the scopeof the invention. For example, any formulas given above are merelyrepresentative of procedures that may be used. Functionality may beadded or deleted from the block diagrams and operations may beinterchanged among functional blocks. Steps may be added or deleted tomethods described within the scope of the present invention.

We claim:
 1. A method of optimizing the layout of power controlcircuitry, of a multiphase power controller, the method including thestep of: (a) placing groups of single or paralleled power transistors(low-side and high-side switching) belonging to each phase in a threephase power control application in a radial symmetric manner about acentral point on a printed circuit board (PCB), and wherein each phasepower transistor group includes multiple power transistors and furthercomprising placing phase output power wire PCB connections in the middleof each power transistor group geometry to physically reduce the PCBcopper track resistance in each phase.
 2. A method as claimed in claim 1wherein the power transistors are placed on the top or bottom of thePCB.
 3. A method as claimed in claim 1 further comprising placing onlythe low-side or the high-side switching power transistors on one side ofthe PCB.
 4. A method as claimed in claim 1 placing both the low-side orthe high-side switching power transistors on one side of the PCB.
 5. Amethod as claimed in claim 1, the method including the step of: (b)applying a radially symmetrical PCB design in three-phase power controlapplications such as radio-controlled (R/C) BLDC motor controllers andBLDC motors with the PCB and motor controller hardware built inside themotor.
 6. A method as claimed in claim 1 further comprising placing thepower transistor group geometry into a bent-line configuration on thePCB, wherein the middle point of the power transistor group geometry isphysically bent at an angle towards the center of the PCB in order toreduce the footprint and size of the PCB.
 7. A method as claimed inclaim 1 further comprising placing phase output power wire PCBconnections around the circumference of the PCB in a radial symmetricmanner about a central point on the PCB.
 8. A method of optimizing thelayout of power control circuitry, of a multiphase power controller, themethod including the steps of: (a) placing groups of single orparalleled power transistors (low-side and high-side switching)belonging to each phase in a three phase power control application in aradial symmetry manner about the center of a PCB; and (b) applying aradially symmetrical PCB design in three-phase power controlapplications such as R/C electric vehicle BLDC motor controllers andBLDC motors with the PCB and controller hardware built inside the motor.